Sy195-205-215-225c9 Manual 2014-11-13 PDF

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Shop Manual SY195/205/215/225C9

Crawler Hydraulic
Crawler Hydraulic Excavator

Excavator
SY195C9
SY205C9
SY215C9
SY225C9
SANY HEAVY MACHINERY LIMITED
318A, Lianggang Avenue, Lingang Industrial Park, Fengxian District, Shanghai, P.R. of China 201413
Tel: (86) 21 5700 8518

Service hotline: (86) 4006 098 318
E-mail: [email protected]
Documentation No.: B06T03ENAN1-SY195/205/215/225C9
Shop Manual
SY195/205/215/225C9
Crawler Hydraulic Excavator
Shop Manual
● Compiled for experienced technicians, this shop manual aims to provide technical information
required for maintenance and repair of the machine.
● Work equipment or optional components not available locally may be included in this shop
manual. Consult authorized Sany dealers for information on these parts and components. Ma-
terial or technical specification is subject to change without prior notice.
WARNING
Read and follow the safety precautions and
instructions in this manual and on the ma-
chine decals. Failure to do so may cause
serious injury, death or property damage.
SY195/205/215/225C9 Crawler Hydraulic Excavator Table of Contents
Table of Contents
1 Introduction
1.1 How to Read the Shop Manual ................................................................................ 1-3
1.2 Terms for Maintenance Standard............................................................................. 1-5
1.3 Handling Electrical and Hydraulic Components....................................................... 1-7
1.3.1 Points to remember when handling electric components .............................. 1-7
1.3.2 Points to remember when handling hydraulic equipment ............................ 1-16
1.4 Hose Connector ..................................................................................................... 1-18
1.4.1 Type of hose connector................................................................................ 1-19
1.4.2 Hose connector tightening torque table ....................................................... 1-19
1.4.3 Connection of O-rings .................................................................................. 1-20
1.5 Table of Standard Tightening Torques .................................................................. 1-21
1.6 Type of Bolts .......................................................................................................... 1-22
1.7 Tightening Sequence ............................................................................................. 1-22
1.8 Maintenance of Half Flanges ................................................................................. 1-23
1.8.1 Table of tightening torques for half flange bolts ........................................... 1-23
1.9 Conversion Table ................................................................................................... 1-24
2 Shop Safety
2.1 Hazard Alert Information .......................................................................................... 2-3
2.2 General Shop Safety ............................................................................................... 2-6
2.2.1 Rules and shop behavior ............................................................................... 2-7
2.2.2 Housekeeping ................................................................................................ 2-7
2.2.3 Shop Liquids Storage..................................................................................... 2-8
2.2.4 Cleaning Parts ............................................................................................... 2-8
2.2.5 Jacking Up the Machine................................................................................. 2-9
2.2.6 Electrical Dangers .......................................................................................... 2-9
2.2.7 Removing Attachments ................................................................................ 2-10
2.2.8 Cleaning the Machine .................................................................................. 2-10
2.2.9 Using the Correct Tools................................................................................ 2-10
2.2.10 Hoisting a Load ...........................................................................................2-11
2.2.11 Appropriate Working Apparel ..................................................................... 2-12
2.2.12 Safety Partners .......................................................................................... 2-12
2.2.13 Two people when engine running .............................................................. 2-13
2.2.14 Driving Pins ................................................................................................ 2-13
2.2.15 Aligning Parts or Components ................................................................... 2-14
Shop Manual - November 2014 I

Table of Contents SY195/205/215/225C9 Crawler Hydraulic Excavator
2.2.16 Fire Extinguisher and Emergency Exits ..................................................... 2-14

2.2.17 Personal Protective Equipment.................................................................. 2-14
2.2.18 Running the Machine ................................................................................. 2-15
2.2.19 Accumulator ............................................................................................... 2-16
2.2.20 Adding Fluids to a System ......................................................................... 2-16
2.2.21 Track Recoil Springs .................................................................................. 2-17
2.2.22 High-Pressure Fluid Lines.......................................................................... 2-17
2.2.23 Safe Work Preparations ............................................................................. 2-18
2.2.24 Mounting and Dismounting ........................................................................ 2-19
2.2.25 Battery Hazards ......................................................................................... 2-20
2.2.26 Jump-Start Safety ...................................................................................... 2-21
2.2.27 Disconnecting the System Power .............................................................. 2-21
2.2.28 Lockout/tagout ........................................................................................... 2-22
2.2.29 Sequence of Procedures ........................................................................... 2-22
2.2.30 Chemical hazard ........................................................................................ 2-24
2.2.31 Material Safety Data Sheets (MSDS) ........................................................ 2-24
2.3 Precautions for sling work and giving signals ........................................................ 2-25
3 Specifications
3.1 Dimensions .............................................................................................................. 3-3
3.2 Working Ranges ...................................................................................................... 3-4
3.3 Technical Specifications........................................................................................... 3-5
3.4 Weight Table ............................................................................................................ 3-8
3.5 Recommended Oil, Fuel and Coolant...................................................................... 3-9
3.6 Capacity Table ....................................................................................................... 3-10
3.7 Engine Performance Curve ....................................................................................3-11
4 Structure and Function

4.1 Engine and Cooling System .................................................................................... 4-5
4.1.1 Engine-related parts....................................................................................... 4-5
4.1.2 Radiator and intercooler................................................................................. 4-6
4.2 Power Train.............................................................................................................. 4-7
4.2.1 Power transmission system .......................................................................... 4-7
4.2.2 Final drive assembly ...................................................................................... 4-8
4.2.3 Swing machinery...........................................................................................4-11
4.2.4 Swing bearing .............................................................................................. 4-13
4.3 Undercarriage and Frame...................................................................................... 4-14
4.3.1 Track frame and recoil spring....................................................................... 4-14
II Shop Manual - November 2014

4.3.2 Idler .............................................................................................................. 4-16

4.3.3 Carrier roller ................................................................................................. 4-18
4.3.4 Track roller ................................................................................................... 4-19
4.3.5 Track shoe ................................................................................................... 4-20
4.3.6 Triple grouser shoe ...................................................................................... 4-23
4.4 Hydraulic System, Part 1 ....................................................................................... 4-24
4.4.1 Hydraulic equipment layout.......................................................................... 4-24
4.4.2 Hydraulic tank and filter ............................................................................... 4-26
4.4.3 Hydraulic pump ................................................................................................... 4-27
4.4.4 Pilot pump .................................................................................................... 4-34
4.4.5 Regulator .................................................................................................... 4-35
4.4.5.1 Control mechanism makeup ............................................................... 4-37
4.4.5.2 Adjustment of the regulator ................................................................. 4-38
4.4.5.3 Operation ............................................................................................ 4-40
4.5.1 Control valve ................................................................................................ 4-43
4.5.2 Operating principle ....................................................................................... 4-46
4.5.2.1 When spool is in neutral position ........................................................ 4-46
4.5.2.2 Travel .................................................................................................. 4-48
4.5.2.3 Arm...................................................................................................... 4-49
4.5.2.4 Boom................................................................................................... 4-54
4.5.2.5 Bucket ................................................................................................. 4-57
4.5.2.6 Swing .................................................................................................. 4-59
4.5.2.7 Option ................................................................................................. 4-61
4.5.2.8 Travel straight ..................................................................................... 4-62
4.5.2.9 Lock valve function ............................................................................. 4-63
4.5.2.10 Main relief valve function .................................................................. 4-65
4.5.2.11 Port relief valve function .................................................................... 4-66
4.5.3 Section view ................................................................................................. 4-70
4.6.1 Swing motor ................................................................................................. 4-81
4.6.2 Swing holding brake..................................................................................... 4-83
4.6.3 Relief valve portion ...................................................................................... 4-84
4.6.4 Reverse prevention valve ............................................................................ 4-86
4.6.4.1 Operation drawing............................................................................... 4-86
4.6.4.2 Explanatory drawing of effects ............................................................ 4-87
4.6.5 Center swivel joint ........................................................................................ 4-89
4.6.6 Travel motor ................................................................................................. 4-91
Shop Manual - November 2014 III

4.6.6.1 Operation of components.................................................................... 4-95

4.6.7 Valve control system .................................................................................. 4-107
4.6.8 Pilot valve.................................................................................................. 4-109
4.6.8.1 Work equipment and swing pilot valve.............................................. 4-109
4.6.8.2 Travel PPC valve ...............................................................................4-113
4.6.9 Solenoid valve.............................................................................................4-117
4.6.10 Accumulator ..............................................................................................4-118
4.6.11 Pilot oil filter ...............................................................................................4-119
4.6.12 Pump oil pressure sensor ........................................................................ 4-120
4.6.13 Hydraulic cylinder..................................................................................... 4-121
4.6.14 Work equipment ....................................................................................... 4-123
4.7 Air Conditioning System....................................................................................... 4-129
4.7.1 A/C components layout drawing ................................................................ 4-130
4.7.2 Control panel.............................................................................................. 4-131
4.7.3 Circuit diagram ........................................................................................... 4-132
4.7.4 Refrigeration principle ................................................................................ 4-134
4.7.4.1 Refrigeration cycle diagram .............................................................. 4-134
4.7.4.2 Heating cycle diagram ...................................................................... 4-134
4.7.5 Compressor ............................................................................................... 4-135
4.7.6 Clutch ......................................................................................................... 4-137
4.7.8 Condenser ................................................................................................. 4-138
4.7.7 Expansion valve ......................................................................................... 4-138
4.7.9 Evaporator ................................................................................................. 4-139
4.7.10 Receiver tank ........................................................................................... 4-139
4.7.11 Pressure switch ........................................................................................ 4-140
4.7.12 Fresh air sensor ....................................................................................... 4-141
4.7.13 Refrigerant ............................................................................................... 4-141
4.7.14 Compressor oil ......................................................................................... 4-160
4.8 Engine Control ..................................................................................................... 4-161
4.8.1 System operation ...................................................................................... 4-162
4.8.2 Components............................................................................................... 4-163
4.8.2.1 Fuel control dial................................................................................. 4-163
4.8.2.2 Controller .......................................................................................... 4-165
4.9 Electrical Control System..................................................................................... 4-167
4.9.1 Control function .......................................................................................... 4-167
4.9.2 Machine control system diagram ............................................................... 4-168
4.9.3 Engine and pump composite control function ............................................ 4-170
4.9.4 Pump control function ................................................................................ 4-174
IV Shop Manual - November 2014

4.9.4.1 Electrical positive flow control ........................................................... 4-175

4.9.4.2 Constant power control ..................................................................... 4-178
4.9.5 Valve control function ................................................................................. 4-180
4.9.5.1 Bucket flow control ............................................................................ 4-181
4.9.5.2 Swing priority control......................................................................... 4-182
4.9.6 Duo travel speed control ............................................................................ 4-183
4.9.7 Engine preheating/overheating alarm ....................................................... 4-185
4.9.7.1 Engine preheating ............................................................................. 4-186
4.9.7.2 Engine overheating alarm ................................................................. 4-187
4.9.8 Engine oil under–pressure alarm ............................................................... 4-187
4.9.9 Auto deceleration/acceleration control ....................................................... 4-188
4.9.10 Engine speed calibration function ............................................................ 4-190
4.9.11 Electrical Components ............................................................................. 4-192
4.9.11.1 Pump pressure sensor .................................................................... 4-192
4.9.11.2 Pilot pressure sensor ...................................................................... 4-193
4.9.11.3 Engine speed sensor ...................................................................... 4-194
4.9.11.4 Coolant temperature sensor............................................................ 4-195
4.9.11.5 Fuel level sensor ............................................................................. 4-196
4.9.11.6 Oil pressure switch .......................................................................... 4-197
4.10 Monitoring System ............................................................................................. 4-198
4.10.1 Machine monitor ...................................................................................... 4-199
4.10.2 Monitor functions...................................................................................... 4-200
4.10.3 Monitor operation ..................................................................................... 4-203
5 Standard Values
5.1 Standard Values of Engine - related Parts............................................................... 5-3
5.2 Standard Values of Chassis-related Parts ............................................................... 5-4
6 Testing and Adjusting

6.1 Engine Speed - Test and Calibrate .......................................................................... 6-3
6.1.1 Testing ........................................................................................................... 6-3
6.1.2 Adjusting ........................................................................................................ 6-3
6.2 Exhaust Gas Color - Test ......................................................................................... 6-6
6.3 Valve Clearance - Adjust.......................................................................................... 6-8
6.3.1 Testing............................................................................................................ 6-8
6.3.2 Adjusting ...................................................................................................... 6-10
6.4 Compression Pressure - Measure ..........................................................................6-11
6.5 Fuel Injection Timing - Test and Adjust .................................................................. 6-13
Shop Manual - November 2014 V

6.5.1 Testing.......................................................................................................... 6-13

6.5.2 Adjusting ...................................................................................................... 6-15
6.6 Engine Oil Pressure - Measure.............................................................................. 6-17
6.7 Engine Speed Sensor - Adjust ............................................................................... 6-19
6.8 A/C Compressor Belt Tension - Test and Adjust ................................................... 6-20
6.8.1 Testing ......................................................................................................... 6-20
6.8.2 Adjusting ...................................................................................................... 6-20
6.9 Swing Bearing Clearance - Measure ..................................................................... 6-22
6.10 Track Tension - Test and Adjust ........................................................................... 6-24
6.10.1 Testing........................................................................................................ 6-24
6.10.2 Adjusting .................................................................................................... 6-25
6.11 Hydraulic Pressure in Hydraulic Circuits - Test and Adjust .................................. 6-26
6.11.1 Measuring .................................................................................................. 6-26
6.11.2 Adjusting..................................................................................................... 6-28
6.12 Control Circuit Oil Pressure - Test and Adjust...................................................... 6-30
6.12.1 Testing........................................................................................................ 6-30
6.12.2 Adjusting .................................................................................................... 6-31
6.13 Solenoid Valve Output Pressure - Measure......................................................... 6-32
6.14 Pilot Valve Output Pressure - Measure................................................................ 6-34
6.15 Pilot Valves (Work Equipment and Swing) - Adjust ............................................. 6-36
6.16 Work Equipment Hydraulic Drift - Test ................................................................. 6-37
6.17 Residual Pressure in Hydraulic Circuit - Release ................................................ 6-40
6.18 Oil Leakage - Measure ........................................................................................ 6-41
6.19 Air in Each Component - Bleed............................................................................ 6-46
7 Troubleshooting
7.1 Points to Remember When Troubleshooting ........................................................... 7-3
7.2 Troubleshooting Procedures .................................................................................... 7-5
7.3 Connector Location and Electrical Circuit Diagram ................................................. 7-8
7.3.1 Connector location layout ............................................................................ 7-12
7.3.2 Electrical element circuit diagram (cab circuit)............................................. 7-18
7.3.3 Electrical control circuit diagram (engine circuit).......................................... 7-20
7.3.4 Electrical control circuit diagram (sensor and solenoid valve circuit) ........... 7-22
7.3.5 SWP type connector .................................................................................... 7-23
7.3.6 A/AMP type connector ................................................................................. 7-24
7.3.7 DT type connector ....................................................................................... 7-25
7.4 Failure Symptoms and Troubleshooting Codes ..................................................... 7-26
7.5 Troubleshooting with an Event Code ..................................................................... 7-28
VI Shop Manual - November 2014

7.6 Troubleshooting of Electrical System (E - Mode)................................................... 7-63

7.7 Troubleshooting of Hydraulic and Mechanical Systems (H - Mode) ...................... 7-93
8 Disassembly and Assembly

8.1 How to Read This Manual ....................................................................................... 8-5
8.1.1 Removing and Installing an Assembly ........................................................... 8-5
8.1.2 Disassembling and assembling an assembly ................................................ 8-5
8.1.3 Special tools................................................................................................... 8-5
8.2.1 The symbols used in this section .................................................................. 8-6
8.2 Operating Precautions ............................................................................................. 8-6
8.3 Start Motor AS - Remove and Install ..................................................................... 8-10
8.3.1 Removal ....................................................................................................... 8-10
8.3.2 Installation .................................................................................................... 8-10
8.4 Injection Pump AS - Remove and Install ................................................................8-11
8.4.1 Removal ........................................................................................................8-11
8.4.2 Installation .................................................................................................... 8-13
8.5 Engine Front Seal - Remove and Install ................................................................ 8-15
8.5.1 Removal ....................................................................................................... 8-15
8.5.2 Installation .................................................................................................... 8-15
8.6 Engine Rear Seal - Remove and Install................................................................. 8-16
8.6.1 Removal ....................................................................................................... 8-16
8.6.2 Installation .................................................................................................... 8-17
8.7 Cylinder Head AS - Remove and Install ................................................................ 8-18
8.7.1 Removal ....................................................................................................... 8-18
8.7.2 Installation .................................................................................................... 8-22
8.8 Radiator AS - Remove and Install.......................................................................... 8-24
8.8.1 Removal ....................................................................................................... 8-24
8.8.2 Installation .................................................................................................... 8-27
8.9 Engine and Hydraulic Pump AS - Remove and Install .......................................... 8-28
8.9.1 Removal ....................................................................................................... 8-28
8.9.2 Installation .................................................................................................... 8-34
8.10 Final Drive AS - Remove and Install .................................................................... 8-35
8.10.1 Removal ..................................................................................................... 8-35
8.10.2 Installation .................................................................................................. 8-36
8.11 Final Drive AS - Disassemble and Assemble ....................................................... 8-37
8.11.1 Disassembly ............................................................................................... 8-37
8.11.2 Assembly .................................................................................................... 8-41
8.12 Swing Motor and Swing Drive AS - Remove and Install ...................................... 8-46
Shop Manual - November 2014 VII

8.12.1 Removal ..................................................................................................... 8-46

8.12.2 Installation .................................................................................................. 8-47
8.13 Swing Motor and Swing Drive AS - Disassemble and Assemble......................... 8-48
8.13.1 Disassembly............................................................................................... 8-48
8.13.2 Assembly.................................................................................................... 8-53
8.14 Idler AS - Disassemble and Assemble ................................................................. 8-58
8.14.1 Disassembly............................................................................................... 8-58
8.14.2 Assembly.................................................................................................... 8-59
8.15 Sprocket - Remove and Install............................................................................. 8-62
8.15.1 Removal ..................................................................................................... 8-62
8.15.2 Installation .................................................................................................. 8-62
8.16 Track AS - Remove and Install ............................................................................ 8-63
8.16.1 Removal ..................................................................................................... 8-63
8.16.2 Installation .................................................................................................. 8-65
8.17 Swing Bearing AS - Remove and Install .............................................................. 8-66
8.17.1 Removal ..................................................................................................... 8-66
8.17.2 Installation .................................................................................................. 8-67
8.18 Swing Platform AS - Remove and Install ............................................................. 8-68
8.18.1 Removal ..................................................................................................... 8-68
8.18.2 Installation .................................................................................................. 8-71
8.19 Swivel Joint AS - Remove and Install .................................................................. 8-72
8.19.1 Removal ..................................................................................................... 8-72
8.19.2 Installation .................................................................................................. 8-74
8.20 Swivel Joint AS - Disassemble and Assemble ..................................................... 8-75
8.20.1 Disassembly............................................................................................... 8-75
8.20.2 Assembly.................................................................................................... 8-76
8.21 Hydraulic Tank AS - Remove and Install.............................................................. 8-77
8.21.1 Removal ..................................................................................................... 8-77
8.21.2 Installation .................................................................................................. 8-79
8.22 Control Valve AS - Remove and Install ................................................................ 8-80
8.22.1 Removal ..................................................................................................... 8-80
8.22.2 Installation .................................................................................................. 8-84
8.23 Hydraulic Pump AS - Remove and Install ............................................................ 8-85
8.23.1 Removal ..................................................................................................... 8-85
8.23.2 Installation .................................................................................................. 8-89
8.24 Middle Oil Seal (Hydraulic Pump Input Shaft)- Remove and Install .................... 8-90
8.24.1 Removal ..................................................................................................... 8-90
8.24.2 Installation .................................................................................................. 8-90
VIII Shop Manual - November 2014

8.25 Pilot Valve AS (Work Equipment) - Disassemble and Assemble ......................... 8-91
8.25.1 Assembly.................................................................................................... 8-91
8.26 Pilot Valve AS (Travel) - Disassemble and Assemble .......................................... 8-93
8.26.1 Assembly.................................................................................................... 8-93
8.27 Hydraulic Cylinder AS - Disassemble and Assemble........................................... 8-94
8.27.1 Disassembly............................................................................................... 8-95
8.27.2 Assembly.................................................................................................. 8-100
8.28 Work Equipment AS - Remove and Install......................................................... 8-105
8.28.1 Removal ................................................................................................... 8-105
8.28.2 Installation ................................................................................................ 8-107
8.29 Air Conditioner AS - Remove and Install............................................................ 8-108
8.29.1 Removal ................................................................................................... 8-108
8.29.2 Installation .................................................................................................8-112
8.30 Counterweight AS - Remove and Install .............................................................8-113
8.30.1 Removal ....................................................................................................8-113
8.30.2 Installation .................................................................................................8-114
8.31 Cab AS - Remove and Install..............................................................................8-115
8.31.1 Removal ....................................................................................................8-115
8.31.2 Installation .................................................................................................8-119
8.32 Cab Window Glass – Disassemble and Assemble ............................................ 8-120
8.32.1 Removal ................................................................................................... 8-121
8.32.2 Installation ................................................................................................ 8-125
8.33 Front Window AS - Disassemble and Assemble................................................ 8-138
8.33.1 Disassemble ............................................................................................ 8-138
8.33.2 Assemble ................................................................................................. 8-141
8.34 Monitor - Remove and Install ............................................................................. 8-146
8.34.1 Removal ................................................................................................... 8-146
8.34.2 Installation ................................................................................................ 8-146
8.35 Controller AS - Remove and Install.................................................................... 8-147
8.35.1 Removal ................................................................................................... 8-147
8.35.2 Installation ................................................................................................ 8-147
8.36 Radio ................................................................................................................. 8-148
8.36.1 Structure .................................................................................................. 8-148
8.36.2 Removal ................................................................................................... 8-149
8.36.3 Installation ................................................................................................ 8-150
8.36.4 Connector model and wiring .................................................................... 8-150
8.37 Battery ............................................................................................................... 8-151
8.37.1 Structure .................................................................................................. 8-151
Shop Manual - November 2014 IX

8.37.2 Removal ................................................................................................... 8-152

8.37.3 Installation ................................................................................................ 8-153
8.37.4 Replacement ............................................................................................ 8-153
8.38 Start Switch........................................................................................................ 8-154
8.38.1 Structure ................................................................................................. 8-154
8.38.2 Removal ................................................................................................... 8-155
8.39 Fuse Box............................................................................................................ 8-157
8.39.1 Removal ................................................................................................... 8-157
8.40 Wiper ................................................................................................................. 8-158
8.40.1 Structure .................................................................................................. 8-158
8.40.2 Working principle ..................................................................................... 8-158
8.40.3 Removal ................................................................................................... 8-159
8.40.5 Installation ................................................................................................ 8-160
8.40.4 Angle adjustment of wiper arm................................................................. 8-160
8.41 Relay.................................................................................................................. 8-161
8.41.1 Engine relays ........................................................................................... 8-161
8.41.2 Other relays ............................................................................................. 8-162
8.42 Sensor ............................................................................................................... 8-165
8.43 Connector Terminals - Insert and Remove ........................................................ 8-167
8.43.1 Insertion ................................................................................................... 8-167
8.43.2 Removal ................................................................................................... 8-168
9 System Schematics
9.1 Hydraulic System Diagram ...................................................................................... 9-3
9.2 Air-Conditioning Electrical Circuit Diagram .............................................................. 9-4
9.3 Fuse Box Relay ....................................................................................................... 9-5
9.4 Control Switches and Monitor Electrical Diagram ................................................... 9-6
9.5 Operator Cab Electrical Circuit Diagram.................................................................. 9-7
9.6 Chassis Electrical Circuit Diagram........................................................................... 9-8
X Shop Manual - November 2014

SY195/205/215/225C9 Crawler Hydraulic Excavator Introduction
Introduction
.
1 Introduction
De al
pt
1.1 How to Read the Shop Manual ................................................................................ 1-3
1.2 Terms for Maintenance Standard............................................................................. 1-5
g n
1.3 Handling Electrical and Hydraulic Components....................................................... 1-7
o
1.3.1 Points to remember when handling electric components .............................. 1-7
in ti
1.3.2 Points to remember when handling hydraulic equipment ............................ 1-16

1.4 Hose Connector ..................................................................................................... 1-18
1.4.1 Type of hose connector................................................................................ 1-19
et a
1.4.2 Hose connector tightening torque table ....................................................... 1-19

n
1.4.3 Connection of O-rings .................................................................................. 1-20

rk er
1.5 Table of Standard Tightening Torques .................................................................. 1-21

1.6 Type of Bolts .......................................................................................................... 1-22
1.7 Tightening Sequence ............................................................................................. 1-22
Ma t
1.8 Maintenance of Half Flanges ................................................................................. 1-23

In
1.8.1 Table of tightening torques for half flange bolts ........................................... 1-23
1.9 Conversion Table ................................................................................................... 1-24
Shop Manual - November 2014 1-1

Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator
.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In
WARNING
Read and understand all safety precau-
tions and instructions in this manual be-
fore reading any other manuals provided
with this machine and before operating or
servicing the machine. Also read the safety
information on machine decals before per-
forming any operations. Failure to do so
can cause machine damage, personal in-
jury or death.
1-2 Shop Manual - November 2014

1 INTRODUCTION
1.1 How to Read the Shop Manual

1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a work-
shop. For ease of understanding, the manual is divided into the following sections.
Introduction
This section provides an overview of what is covered in the rest of this manual and how to use
this manual,.
.
De al
Shop Safety
pt
This section covers basic shop safety information relating to this equipment. It also describes
what the hazard alerts mean that are used throughout the manual.
g n
Specifications
o
Technical specification of work equipment and optional parts are given in this section.
in ti
Structure and function

et a
This section explains the structure and function of each component. It helps the reader to get a
better understanding of the machine structure, and also serves as a reference for troubleshoot-
n
ing.
rk er
Standard Values
This section explains the standard values for a new machine and judgement criteria for testing,
Ma t
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
In
Testing and adjusting
This section details the inspection before and after repair work as well as the adjustment during
inspection and repair work. Troubleshooting table that involves “Fault”and “Cause”are also in-
cluded in this section.
Troubleshooting
This section explains the way to detect faulty parts and the method to repair them. This section is
divided into the following parts: Electrical system, Engine, Hydraulic and mechanical system and
Monitoring system.
Disassembly and assembly
This section explains the procedures as well as precautions for removing, installing, disassem-
bling and assembling of each component.

System Schematics
This section provides hydraulic circuit diagrams and electrical circuit diagrams.
2. Revision and distribution
Any additions, revisions, or other change of notices will be sent to Sany distributors. Get the most
up-to-date information before you start any work.
3. Units
In this shop manual, the units are indicated with International System of units (SI). For reference,
conventionally used Gravitational System of units is indicated in parentheses { }.
.
De al
pt
4. Symbols g n
Important safety and quality portions are marked with the following symbols so that the shop
manual will be used practically.
o
in ti
Symbol Item Remarks
Special safety precautions are necessary when performing

Safety
et a
work.
n
Special technical precautions or other precautions for pre-

Caution
serving standards are necessary when performing work.
rk er
Weight of parts of component or parts. Caution necessary

kg Weight when selecting hoisting wire, or when working posture is
Ma t
important, etc.
Tightening Places that require special attention for tightening torque
In
torque during assembly.
Coat Places to be coated with adhesives, etc. during assembly.
Oil, Coolant Places where oil, etc. must be added, and capacity.
Places where oil, etc. must be drained, and quantity to be

Drain
drained.

1.2 Terms for Maintenance Standard
The maintenance standard values necessary

for judgment of products and parts are de-
scribed by the following terms.
1. Standard size and tolerance
● To be accurate, the finishing size of parts

is a little different from one to another.
● To specify a finishing size of a part, a tem-

porary standard size is set and an allow-
.
able difference from that size is indicated.
De al
pt
● The above size set temporarily is called
the "standard size" and the range of differ-
g n
ence from the standard size is called the
"tolerance".
o
● The tolerance with the symbols of + or – is
in ti
indicated on the right side of the standard

size.
et a
Example
n
rk er
Standard size Tolerance

–0.022
120
–0.126
Ma t
NOTE: The tolerance may be indicated in

In
the text and a table as [standard size (upper Std.size F 60

limit of tolerance/lower limit of tolerance)]. Tolerance of hole
(upper):+0.046
Example) 120 (–0.022/–0.126) Std.clearance (max.):0.122
Std.clearance (min.):0.030
● Usually, the size of a hole and the size
Tolerance of shaft
of the shaft to be fitted to that hole are (lower):-0.076
indicated by the same standard size Tolerance of shaft
(upper):-0.030
and different tolerances of the hole and
shaft. The tightness of fit is decided by
the tolerance.
● Indication of size of rotating shaft and

hole and relationship drawing of them.
ZX215-1000003

Example 4. Repair limit and allowable value
Tolerance ● The size of a part changes due to wear

Standard size and deformation while it is used. The limit
Shaft Hole
of changed size is called the "repair limit".
-0.030 +0.046
φ60
-0.076 0 ● If a part is worn to the repair limit must be
replaced or repaired.
2. Standard clearance and standard value
● The performance and function of a product
● The clearance made when new parts are lowers while it is used. A value below which
assembled is called the "standard clear- the product can be used without causing a
ance", which is indicated by the range from problem is called the "allowable value".
the minimum clearance to the maximum
● If a product is worn to the allowable value,
.
clearance.
De al
it must be checked or repaired. Since the
pt
● When some parts are repaired, the clear- permissible value is estimated from vari-
ance is generally adjusted to the standard
g n ous tests or experiences in most cases,
clearance. however, it must be judged after consider-
ing the operating condition and customer's
o
● A value of performance and function of requirement.
new products or equivalent is called the
in ti
"standard value", which is indicated by a 5. Clearance limit

range or a target value.
● Parts can be used until the clearance be-
et a
● When some parts are repaired, the value tween them is increased to a certain limit.
of performance/function is set to the stan- The limit at which those parts cannot be
n
dard value. used is called the "clearance limit".

rk er
3. Standard interference ● If the clearance between the parts exceeds

the clearance limit, they must be replaced
● When the size of a hole is smaller than the or repaired.
Ma t
size of a shaft because of the standard

size and tolerance, the difference between 6. Interference limit
In
these sizes is called the "interference".

● The allowable maximum interference be-
● The range (A – B) from the difference (A) tween the hole of a part and the shaft of
between the minimum size of the shaft and another part to be assembled is called the
the maximum size of the shaft to the differ- "interference limit".
ence (B) between the maximum size of the
● The interference limit shows the repair limit
shaft and the minimum size of the hole is
of the part of smaller tolerance.
the "standard interference".
● If the interference between the parts ex-
● After repairing or replacing some parts,
ceeds the interference limit, they must be
measure the size of their hole and shaft
replaced or repaired.
and check that the interference is in the
standard range.

1.3 Handling Electrical and Hydraulic Components
To maintain the performance of the machine

over a long period, and to prevent failures or
other troubles before they occur, correct "oper-
ation", "maintenance and inspection", "trouble-
shooting", and "repairs" must be carried out.
This section deals particularly with correct re-
pair procedures for mechatronics and is aimed
at improving the quality of repairs. For this
purpose, it gives sections on "Handling electric
components" and "Handling hydraulic equip-
ment" (particularly gear oil and hydraulic oil).
.
De al
pt
1.3.1 Points to remember when handling electric components
g n
1. Handling wiring harnesses and connec-
o
tors
in ti
Wiring harnesses consist of wiring con-

necting one component to another compo-
nent, connectors used for connecting and
et a
disconnecting one wire from another wire,

n
and protectors or tubes used for protecting

the wiring.
rk er
Compared with other electrical compo-

nents fitted in boxes or cases, wiring
Ma t
harnesses are more likely to be affected

by the direct effects of rain, water, heat, or
In
vibration. Furthermore, during inspection

and repair operations, they are frequently ZX215-1000004
removed and installed again, so they are
likely to suffer deformation or damage. For
this reason, it is necessary to be extremely
careful when handling wiring harnesses.

2. Main failures occurring in wiring har-

ness
1) Defective contact of connectors (defective

contact between male and female)
Problems with defective contact are likely Improper insertion
to occur because the male connector is not

properly inserted into the female connector,
or because one or both of the connectors
is deformed or the position is not correctly
aligned, or because there is corrosion or
oxidation of the contact surfaces.
.
ZX215-1000005
De al
pt
2) Defective crimping or soldering of connec-
g n
tors
Crimped portion
o
The pins of the male and female connec-
tors are in contact at the crimped terminal
in ti
or soldered portion, but if there is exces-

sive force brought to bear on the wiring,
the plating at the joint will peel and cause
et a
improper connection or breakage.

n
rk er
ZX215-1000006
3) Disconnections in wiring
Ma t
If the wiring is held and the connectors are

In
pulled apart, or components are lifted with

a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.
ZX215-1000007

4) High-pressure water entering connector
The connector is designed to make it

difficult for water to enter (drip-proof
structure), but if high-pressure water is
sprayed directly on the connector, water
may enter the connector, depending on the
direction of the water jet. Accordingly, take
care not splash water over the connector.
The connector is designed to prevent
water from entering, but at the same time,
if water does enter, it is difficult for it to
be drained. Therefore, if water should get
into the connector, the pins will be short-
.
De al
ZX215-1000008
circuited by the water, so if any water gets
pt
in, immediately dry the connector or take
other appropriate action before passing
g n
electricity through it.
o
in ti
5) Oil or dirt stuck to connector
If oil or grease are stuck to the connector

et a
and an oil film is formed on the mating

surface between the male and female pins,
n
the oil will not let the electricity pass, so

rk er
there will be defective contact. If there is

oil or grease stuck to the connector, wipe
it off with a dry cloth or blow it dry with
Ma t
compressed air and spray it with a contact

restorer.
In
NOTE:
● When wiping the mating portion of the

ZX215-1000009
connector, be careful not to use exces-
sive force or deform the pins.
● If there is oil or water in the com-

pressed air, the contacts will become
even dirtier, so remove the oil and wa-
ter from the compressed air completely
before cleaning with compressed air.

3. Removing, installing, and drying con-

nectors and wiring harnesses
1) Disconnecting connectors
a. Hold the connectors when disconnect-

ing.
Press lightly
when removing
When disconnecting the connectors,
hold the connectors. For connectors Lock stopper
held by a screw, loosen the screw fully,

then hold the male and female connec-
tors in each hand and pull apart. For
connectors which have a lock stop-
per, press down the stopper with your
.
ZX215-1000010
De al
thumb and pull the connectors apart.
pt
NOTE: Never pull with one hand.
g n
b. When removing from clips
o
● Both of the connector and clip have
Both stoppers
in ti
stoppers, which are engaged with each

other when the connector is installed.
et a
n
rk er
ZX215-1000011
Ma t
In
● When removing a connector from a clip,

pull the connector in a parallel direction
to the clip for removing stoppers.
ZX215-1000012

c. Action to take after removing connec-

tors
After removing any connector, cover

it with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
NOTE: If the machine is left disas-

sembled for a long time, it is particularly
easy for improper contact to occur, so
always cover the connector.
ZX215-1000013
.
De al
2) Connecting connectors
pt
a. Check the connector visually
g n
Check that there is no oil, dirt, or water Clicks into position
o
stuck to the connector pins (mating por-
tion).
in ti
Check that there is no deformation, de-

fective contact, corrosion, or damage to
et a
the connector pins.

n
ZX215-1000022
Check that there is no damage or
breakage to the outside of the connec-
rk er
tor.
NOTE: If there is any oil, water, or dirt

Ma t
stuck to the connector, wipe it off with

a dry cloth. If any water has got inside
In
the connector, warm the inside of the

wiring with a dryer, but be careful not to
make it too hot as this will cause short
circuits.
NOTE: If there is any damage or break-

age, replace the connector.

b. Fix the connector securely.
Align the position of the connector cor-

rectly, and then insert it securely. For
connectors with lock stopper, push in
the connector until the stopper clicks
into position.
c. Correct any protrusion of the boot and

any misalignment of the wiring harness.
For connectors fitted with boots, correct

any protrusion of the boot. In addition, if ZX215-1000014
the wiring harness is misaligned, or the
clamp is out of position, adjust it to its
.
De al
correct position.
pt
NOTE: If the connector cannot be cor-
g n
rected easily, remove the clamp and
adjust the position.
o
● If the connector clamp has been re-
in ti
moved, be sure to return it to its origi-

nal position. Check also that there are
no loose clamps.
et a
n
ZX215-1000015
rk er
3) Connecting DT connectors
Ma t
Since the DT 8-pin and 12-pin heavy duty

2 a 1 c
wire connectors have 2 latches respec-
In
tively, push them in until they click 2 times.
● Male connector: 1
● Female connector: 2
● Normal locking state (Horizontal): a, b,

d d
b
● Incomplete locking state (Diagonal): c ZX215-1000016

4) Drying wiring harness
If there is any oil or dirt on the wiring

harness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do not
use high-pressure water or steam directly
on the wiring harness. If water gets directly
on the connector, do as follows.
a. Disconnect the connector and wipe off

the water with a dry cloth.
NOTE: If the connector is blown dry

with compressed air, there is the risk
.
ZX215-1000009
De al
that oil in the air may cause defective
pt
contact, so remove all oil and water
from the compressed air before blowing
with air.
g no
b. Dry the connector with a dryer.
in ti
If water gets inside the connector, use

a dryer to dry the connector.
et a
NOTE: Hot air from the dryer can be

used, but regulate the time that the
n
hot air is used in order not to make the

rk er
connector or related parts too hot, as ZX215-1000017

this will cause deformation or damage
to the connector.
Ma t
c. Carry out a continuity test on the con-

In
nector.
After drying, leave the wiring harness

disconnected and carry out a continuity
test to check for any short circuits be-
tween pins caused by water.
T adapter
NOTE: After completely drying the con-
nector, blow it with contact restorer and
reassemble.
ZX215-1000018

4. Handling the integrated control monitor
1) The controller contains a microcomputer

and an electronic control circuits. They
control all of the electronic circuits on the
machine, so be extremely careful when
handling the integrated control monitor.
2) Do not place objects on the controller.
3) Cover the control connectors with tape or a
.
vinyl bag. Never touch the connector con- ZX215-1000019
De al
tacts with your hand.
pt
4) Do not leave it where it may be exposed to
g n
rain.
o
Tool
5) Do not place the controller on oil, water, or Box
soil, or in any hot place, even for a short
in ti
time.
6) Precautions for arc welding

et a
When welding on the controller, disconnect

n
all wiring harness connectors connected

to the controller. Fit an arc welding ground
rk er
ZX215-1000020
close to the welding point.

Ma t
In
ZX215-1000021

5. Points to remember when troubleshoot-

ing electric circuits
1) Always turn the power OFF before discon-

necting or connecting connectors.
2) Before carrying out troubleshooting, check

that all the related connectors are properly
inserted.
NOTE: Disconnect and connect the related

connectors several times to check.
3) Always connect any disconnected connec-

tors before going on to the next step.
.
De al
NOTE: If the power is turned ON with the
pt
connectors still disconnected, unnecessary
abnormality displays will be generated.
g n
4) When carrying out troubleshooting of cir-
o
cuits (measuring the voltage, resistance,
in ti
continuity, or current), move the related

wiring and connectors several times and
check that there is no change in the read-
et a
ing of the tester.

n
NOTE: If there is any change, there is

probably defective contact in that circuit.
rk er
Ma t
In

1.3.2 Points to remember when handling hydraulic equipment
With the increase in pressure and precision

of hydraulic equipment, the most common
cause of failure is dirt (foreign material) in the
hydraulic circuit. When adding hydraulic oil, or
when disassembling or assembling hydraulic
equipment, it is necessary to be particularly
careful.
1. Be careful of the operating environment

Avoid adding hydraulic oil, replacing filters,
.
De al
or repairing the machine in rain or high
pt
winds, or places where there is a lot of
dust. g n
2. Disassembly and maintenance work in
o
the field
in ti
If disassembly or maintenance work is

carried out on hydraulic equipment in the
field, there is danger of dust entering the
ZX215-1000023
et a
equipment. It is also difficult to check the

performance after repairs, so it is desir-
n
able to use unit exchange. Disassembly

rk er
and maintenance of hydraulic equipment

should be carried out in a specially pre-
pared dust-proof workshop, and the perfor-
Ma t
mance should be checked with special test

equipment.
In
3. Sealing openings
After any piping or equipment is removed,

the openings should be sealed with caps,
tapes, or vinyl bags to prevent any dirt or
dust from entering. If the opening is left
open or is blocked with a rag, there is
danger of dirt entering or of the surround-
ing area being made dirty by leaking oil so
never do this. Do not simply drain oil out
onto the ground, but collect it and ask the
customer to dispose of it, or take it back
ZX215-1000024
with you for disposal.

4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get

in when refilling with hydraulic oil. Always
keep the oil filler and the area around it
clean, and also use clean pumps and oil
containers. If an oil cleaning device is
used, it is possible to filter out the dirt that
has collected during storage, so this is an
even more effective method.
ZX215-1000025
5. Change hydraulic oil when the tempera-
.
De al
ture is high
pt
When hydraulic oil or other oil is warm, it
flows easily. In addition, the sludge can
g n
also be drained out easily from the circuit
together with the oil, so it is best to change
o
the oil when it is still warm. When changing
in ti
the oil, as much as possible of the old

hydraulic oil must be drained out. (Drain
the oil from the hydraulic tank; also drain
et a
the oil from the filter and from the drain

plug in the circuit.) If any old oil is left, the
n
contaminants and sludge in it will mix with

rk er
the new oil and will shorten the life of the

hydraulic oil.
Ma t
6. Flushing operations
In
After disassembling and assembling the

equipment, or changing the oil, use flush-
Flushing oil
ing oil to remove the contaminants, sludge,
and old oil from the hydraulic circuit.
Normally, flushing is carried out twice:
primary flushing is carried out with flushing
oil, and secondary flushing is carried out
with the specified hydraulic oil.
ZX215-1000026

7. Cleaning operations
After repairing the hydraulic equipment

(pump, control valve, etc.) or when run-
ning the machine, carry out oil cleaning
to remove the sludge or contaminants in
the hydraulic oil circuit. The oil cleaning
equipment is used to remove the ultra fine
(about 3 μ) particles that the filter built in
the hydraulic equipment cannot remove, so
it is an extremely effective device.
ZX215-1000027
.
De al
pt
1.4 Hose Connector
g n
Hose connector is used to connect hoses with
a small diameter. The metal sealing surface (4)
o
of the joint (1) must be in close contact with
1 4 3 5 2
in ti
the metal sealing surface (5) of the hose (2) to
seal pressurized oil.
et a
n
NOTICE
Connector
rk er
● Do not over-tighten the nut (3). Exces-

sive force applied on the metal sealing ZX215-1000028
surface (4) and (5) may cause the joint
Ma t
(1) to break. Be sure to tighten nut (3)

according to technical specifications.
In
● Scratches or other damages on seal-

ing surface (4) and (5) may cause leaks
at the joint. Be extremely careful not
to damage the sealing surfaces during
connecting and disconnecting work.

1.4.1 Type of hose connector
24°
24°
Male Female
ZX215-1000029
1.4.2 Hose connector tightening torque table
.
De al
pt
Wrench size mm Wrench size mm Tightening torque
Type
g n Connecting nut Hose joint N·m(kgf·m,Ibf·ft)
19 19 59(6,44)
o
22 22 98(10,72)
27 27 118(12,87)
in ti
36 36 235(24,173)
24° Male
41 41 295(30,218)
et a
50 50 490(50,361)
n
60 60 670(68,494)
70 70 980(100,723)
rk er
19 17 44(4.5,32)
22 19 59(6,44)
Ma t
27 22 118(12,87)
24° Female
In
36 30, 32 235(24,173)
41 36 295(30,218)
50 46 490(50,361)
NOTICE
● The torque values listed in the table are
intended for general application.
● Do not use torque values listed in this

table when different torque values are
specified for a special purpose.

1.4.3 Connection of O-rings
Place O-ring (6) in contact with the contact

surface of the joint (7) to seal the pressurized
oil. 7 6 9
NOTICE
● Replace o-rings (6) with new ones when
re-connecting hoses. Hose connector
8 10
● Before tightening nut (9), make sure the
.
o-ring (6) has been placed into the o-ring ZX215-1000030
De al
seat (8).Displacement of the o-ring may
pt
have it damaged and cause leaks.
g n
● Be careful not to damage the o-ring seat
(8) or the sealing surface (10). Damaged
o
o-ring (6) may cause oil leakage.
in ti
● If oil leakage due to loosened nut (9) is

detected, do not try to stop the leakage
by tightening nut (9). Instead, replace o-
et a
ring (6) with a new one and make sure it

n
is well positioned, and tighten nut (9).

rk er
Wrench size mm Wrench size mm Tightening torque

Ma t
Connecting nut Hose joint N·m (kgf·m,Ibf·ft)

19 17 44(4.5,32)
In
22 19 59(6,44)
27 22 118(12,87)
36 30, 32 235(24,173)
41 36 295(30,218)
50 46 490(50,361)

1.5 Table of Standard Tightening Torques
Table of tightening torques for bolts and nuts
● Unless specified otherwise, tighten metric nuts and bolts to the torque below. (When using
torque wrench)
Bolt Bolt Wrench Hex wrench Hexagonal bolt Hexagonal socket head bolt
diameter grade size size N·m kgf·m lbf·ft N·m kgf·m lbf·ft
M6 10.9 10 4 13.2 1.37 9.74 13.2 1.37 9.74
M8 10.9 13 6 31 3.16 22.87 31 3.16 22.87
M10 10.9 17 8 66 6.73 48.7 66 6.73 48.7
.
De al
M12 10.9 19 10 113 11.53 83.39 113 11.53 83.39
pt
M14 10.9 22 12 177 18.06 130.6 177 18.06 130.6
M16 10.9 24 14 279 28.47 205.9 279 28.47 205.9
M18
g n
10.9
o
27 14 382 38.98 281.9 382 38.98 281.9
M20 10.9 30 17 549 56.02 405.16 549 56.02 405.16
in ti
M27 10.9 41 19 1320 134.7 974.16 1320 134.7 974.16

M10 12.9 17 6 78 7.96 57.76 78 7.96 57.76
M12 12.9 19 8 137 13.98 101.1 137 13.98 101.1
et a
M16 12.9 24 14 339 34.6 250.18 339 34.6 250.18

n
M20 12.9 30 17 664 67.75 490 664 67.75 490

rk er
NOTICE
The following items apply to fine thread and coarse thread.
Ma t
● Apply grease (zinc white B dissolved in spindle oil) onto the nuts and bolts to reduce
In
the friction coefficient. Thrust bolts do not require greasing.
● Torque tolerance is ±10%.
● Always use bolts of correct length. The tip of bolts with excessive length may contact
the bottom of the bolt hole, resulting in under-tightening. Bolts with inadequate length
may result in insufficient fastening.
● The torque values listed in the table are intended for general application. If different
torque values are specified for a special purpose, the torque values in this table are not
applicable any more.
● Make sure the threads are free of dirt or rusts before installation of nuts and bolts.

1.6 Type of Bolts
Tighten nuts and bolts properly to specified

torque values. The type and grade of bolts are
illustrated on the right.
Hex bolt Socket head hex bolt
Use correct bolts and tighten them properly
when assembling machines or components.
8.8 10.9 12.9
ZX215-1000031
.
1.7 Tightening Sequence
De al
pt
When two or more bolts are being tightened,
Cross tightening Diagonal tightening
follow the tightening sequence shown on the
g n 1 1
right to ensure even tightening.
o
6 3
3 4
4 5
in ti
2 2
CAUTION
Central and diagonal tightening
● Always use suitable tools for specific
et a
12 9 4 1 6 7 14
work. Use of improper tools and meth-
n
ods may cause a hazardous situation.

rk er
13 8 5 2 3 10 11
● Use tools of correct sizes when loosen-
ZX215-1000032
ing or tightening the nuts or bolts. Oth-
erwise, the tools may slide and cause
Ma t
personal injury.
In
ZX215-1000033

1.8 Maintenance of Half Flanges
1. Clean the sealing surface of the flange and

check it carefully. Scratches and coarse-
ness cause leaks or abrasion of seals.
Uneven surface may squeeze the seal out.
If these faults are not corrected properly,
parts may have to be replaced.
2. Always use specified O-rings. Check that

the O-rings are not damaged. Do not file
the surface of the O-ring. Apply grease
onto the O-ring to locate it.
.
De al
ZX215-1000034
pt
3. Tighten the half flanges carefully. Locate
g n
the opening at the center so that it is per-
pendicular to the oil opening. Tighten the
o
Improper
bolt manually to maintain the location of
in ti
the components.
et a
n
rk er
ZX215-1000035
1.8.1 Table of tightening torques for half flange bolts

Ma t
In
● Unless specified otherwise, tighten the half flange bolts to the torques below.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
10 14 59~74 6.0~7.5
12 17 98~123 10.0~12.5
16 22 235~285 23.5~29.5

1.9 Conversion Table

The conversion table in this section is provided to enable simple conversion of figures. For details
of the method of using the conversion table, see the example given below.
Example:
Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches
1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw
a horizontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular
.
line down from (B).
De al
pt
3) Take the point where the two lines cross as (C). This point (C) gives the value when con-
verting from millimeters to inches. Therefore, 55 mm = 2.165 inches.
g n
2. Convert 550 mm into inches
o
1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point
in ti
one place to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.

et a
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the
decimal point one place to the right) to return to the original value. This gives 550 mm =
n
21.65 inches.
rk er
Ma t
In

Length
Millimeters to Inches
(B) 1mm=0.03937in
0 1 2 3 4 5 6 7 8 9
0 0.000 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.535
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
.
De al
(A) 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
pt
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.031 3.071 3.110
80
g n
3.150
o
3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
in ti
Millimeters to Inches
1mm=0.03937in
et a
0 1 2 3 4 5 6 7 8 9
n
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

rk er
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.535
Ma t
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
In
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.031 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Inches to Millimeters
in. mm in. mm
1/64 0.3969 33/64 13.0969
1/32 0.7938 17/32 13.4938
3/64 1.1906 35/64 13.8906
1/16 1.5875 9/16 14.2875
5/64 1.9844 37/64 14.6844
3/32 2.3813 19/32 15.0813
7/64 2.7781 39/64 15.4781
1/8 3.1750 5/8 15.8750
.
De al
9/64 3.5719 41/64 16.2719
pt
5/32 3.9688 21/32 16.6688
11/64 4.3656 43/64 17.0656
3/16
g no
4.7625 11/16 17.4625
13/64 5.1594 45/64 17.8594
in ti
7/32 5.5563 23/32 18.2563
15/64 5.9531 47/64 18.6531
1/4 6.3500 3/4 19.0500
et a
17/64 6.7469 49/64 19.4469

n
9/32 7.1438 25/32 19.8438

rk er
19/64 7.5406 51/64 20.2406

5/16 7.9375 13/16 20.6375
21/64 8.3344 53/64 21.0344
Ma t
11/32 8.7313 27/32 21.4313

In
23/64 9.1281 55/64 21.8281

3/8 9.5250 7/8 22.2250
25/64 9.9219 57/64 22.6219
13/32 10.3188 29/32 23.0188
27/64 10.7156 59/64 23.4156
7/16 11.1125 15/16 23.8125
29/64 11.5094 61/64 24.2094
15/32 11.9063 31/32 24.6063
31/64 12.3031 63/64 25.0031
1/2 12.7000 1 25.4000

Feet to Meters
ft. 0 1 2 3 4 5 6 7 8 9 ft.
m m m m m m m m m m
- - 0.305 0.610 0.914 1.219 1.524 1.829 2.134 2.438 2.743 -
10 3.048 3.353 3.658 3.962 4.267 4.572 4.877 5.182 5.486 5.791 10
20 6.096 6.401 6.706 7.010 7.315 7.620 7.925 8.230 8.534 8.839 20
30 9.144 9.449 9.754 10.058 10.363 10.668 10.973 11.278 11.582 11.887 30
40 12.192 12.497 12.802 13.106 13.411 13.716 14.021 14.326 14.630 14.935 40
50 15.240 15.545 15.850 16.154 16.459 16.764 17.069 17.374 17.678 17.983 50
60 18.288 18.593 18.898 19.202 19.507 19.812 20.117 20.422 20.726 21.031 60
.
De al
70 21.336 21.641 21.946 22.250 22.555 22.860 23.165 23.470 23.774 24.079 70
pt
80 24.384 24.689 24.994 25.298 25.603 25.908 26.213 26.518 26.822 27.127 80
90 27.432 27.737 28.042 28.346 28.651 28.956 29.261 29.566 29.870 30.175 90
100
g n
30.480 30.785 31.090 31.394 31.699 32.004 32.309 32.614 32.918 33.223
o
100
in ti
Meters to Feet
et a
m 0 1 2 3 4 5 6 7 8 9 m
n
ft. ft. ft. ft. ft. ft. ft. ft. ft. ft.
- - 3.2808 6.5617 9.8425 13.1234 16.4042 19.6850 22.9659 26.2467 29.5276 -
rk er
10 32.8084 36.0892 39.3701 42.6509 45.9318 49.2126 52.4934 55.7743 59.0551 62.3360 10
20 65.6168 68.8976 72.1785 75.4593 78.7402 82.0210 85.3018 88.5827 91.8635 95.1444 20
Ma t
30 98.4252 101.7060 104.9869 108.2677 111.5486 114.8294 118.1102 121.3911 124.6719 127.9528 30
In
40 131.2336 134.5144 137.7953 141.0761 144.3570 147.6378 150.9186 154.1995 157.4803 160.7612 40
50 164.0420 167.3228 170.6037 173.8845 177.1654 180.4462 183.7270 187.0079 190.2887 193.5696 50
60 196.8504 200.1312 203.4121 206.6929 209.9738 213.2546 216.5354 219.8163 223.0971 226.3780 60
70 229.6588 232.9396 236.2205 239.5013 242.7822 246.0630 249.3438 252.6247 255.9055 259.1864 70
80 262.4672 265.7480 269.0289 272.3097 275.5906 278.8714 282.1522 285.4331 288.7139 291.9948 80
90 295.2756 298.5564 301.8373 305.1181 308.3990 311.6798 314.9606 318.2415 321.5223 324.8032 90
100 328.0840 331.3648 334.6457 337.9265 341.2074 344.4882 347.7690 351.0499 354.3307 357.6116 100

Miles to Kilometers
miles 0 1 2 3 4 5 6 7 8 9 miles
km km km km km km km km km km
- - 1.609 3.219 4.828 6.437 8.047 9.656 11.265 12.875 14.484 -
10 16.093 17.703 19.312 20.921 22.531 24.140 25.749 27.359 28.968 30.577 10
20 32.187 33.796 35.405 37.015 38.624 40.234 41.843 43.452 45.062 46.671 20
30 48.280 49.890 51.499 53.108 54.718 56.327 57.936 59.546 61.155 62.764 30
40 64.374 65.983 67.592 69.202 70.811 72.420 74.030 75.639 77.248 78.858 40
50 80.467 82.077 83.686 85.295 86.904 88.514 90.123 91.732 93.342 94.951 50
60 96.561 98.170 99.779 101.388 102.998 104.607 106.216 107.826 109.435 111.044 60
.
De al
70 112.654 114.263 115.872 117.482 119.091 120.701 122.310 123.919 125.529 127.138 70
pt
80 128.748 130.357 131.966 133.575 135.185 136.794 138.403 140.013 141.622 143.231 80
90 144.841 146.450 148.059 149.669 151.278 152.887 154.497 156.106 157.715 159.325 90
g n
100 160.934 162.543 164.153 165.762 167.371 168.981 170.590 172.199 173.809 175.418 100
o
in ti
Kilometers to Miles
et a
km 0 1 2 3 4 5 6 7 8 9 km
miles miles miles miles miles miles miles miles miles miles
n
- - 0.621 1.243 1.864 2.485 3.107 3.728 4.350 4.971 5.592 -

rk er
10 6.214 6.835 7.456 8.078 8.699 9.321 9.942 10.563 11.185 11.806 10
20 12.427 13.049 13.670 14.292 14.913 15.534 16.156 16.777 17.398 18.020 20
Ma t
30 18.641 19.262 19.884 20.505 21.127 21.748 22.369 22.991 23.612 24.233 30
40 24.855 25.476 26.098 26.719 27.340 27.962 28.583 29.204 29.826 30.447 40
In
50 31.069 31.690 32.311 32.933 33.554 34.175 34.797 35.418 36.039 36.661 50
60 37.282 37.904 38.525 39.146 39.768 40.389 41.010 41.632 42.253 42.875 60
70 43.496 44.117 44.739 45.360 45.981 46.603 47.224 47.845 48.467 49.088 70
80 49.710 50.331 50.952 51.574 52.195 52.816 53.438 54.059 54.681 55.302 80
90 55.923 56.545 57.166 57.787 58.409 59.030 59.652 60.273 60.894 61.516 90
100 62.137 62.758 63.380 64.001 64.622 65.244 65.865 66.487 67.108 67.729 100

Area
Square inches to square centimeters
in2 0 1 2 3 4 5 6 7 8 9 in2
cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2
- - 6.452 12.903 19.355 25.806 32.258 38.710 45.161 51.613 58.064 -
10 64.516 70.968 77.419 83.871 90.322 96.774 103.226 109.677 116.129 122.580 10
20 129.032 135.484 141.935 148.387 154.838 161.290 167.742 174.193 180.645 187.096 20
30 193.548 200.000 206.451 212.903 219.354 225.806 232.258 238.709 245.161 251.612 30
40 258.064 264.516 270.967 277.419 283.870 290.322 296.774 303.225 309.677 316.128 40
50 322.580 329.032 335.483 341.935 348.386 354.838 361.290 367.741 374.193 380.644 50
.
De al
60 387.096 393.548 399.999 406.451 412.902 419.354 425.806 432.257 438.709 445.160 60
pt
70 451.612 458.064 464.515 470.967 477.418 483.870 490.322 496.773 503.225 509.676 70
80 516.128 522.580 529.031 535.483 541.934 548.386 554.838 561.289 567.741 574.192 80
g n
90 580.644 587.096 593.547 599.999 606.450 612.902 619.354 625.805 632.257 638.708 90
o
100 645.160 651.612 658.063 664.515 670.966 677.418 683.870 690.321 696.773 703.224 100
in ti
Square centimeters to square inches

et a
cm2 0 1 2 3 4 5 6 7 8 9 cm2
n
in2 in2 in2 in2 in2 in2 in2 in2 in2 in2
rk er
- - 0.155 0.310 0.465 0.620 0.775 0.930 1.085 1.240 1.395 -

10 1.550 1.705 1.860 2.015 2.170 2.325 2.480 2.635 2.790 2.945 10
20 3.100 3.255 3.410 3.565 3.720 3.875 4.030 4.185 4.340 4.495 20
Ma t
30 4.650 4.805 4.960 5.115 5.270 5.425 5.580 5.735 5.890 6.045 30
In
40 6.200 6.355 6.510 6.665 6.820 6.975 7.130 7.285 7.440 7.595 40
50 7.750 7.905 8.060 8.215 8.370 8.525 8.680 8.835 8.990 9.145 50
60 9.300 9.455 9.610 9.765 9.920 10.075 10.230 10.385 10.540 10.695 60
70 10.850 11.005 11.160 11.315 11.470 11.625 11.780 11.935 12.090 12.245 70
80 12.400 12.555 12.710 12.865 13.020 13.175 13.330 13.485 13.640 13.795 80
90 13.950 14.105 14.260 14.415 14.570 14.725 14.880 15.035 15.190 15.345 90
100 15.500 15.655 15.810 15.965 16.120 16.275 16.430 16.585 16.740 16.895 100

Volume
Cubic inches to cubic centimeters
in3 0 1 2 3 4 5 6 7 8 9 in3
cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc)
- - 16.387 32.774 49.161 65.548 81.935 98.322 114.709 131.096 147.484 -
10 163.871 180.258 196.645 213.032 229.419 245.806 262.193 278.580 294.967 311.354 10
20 327.741 344.128 360.515 376.902 393.289 409.677 426.064 442.451 458.838 475.225 20
30 491.612 507.999 524.386 540.773 557.160 573.547 589.934 606.321 622.708 639.095 30
40 655.482 671.869 688.257 704.644 721.031 737.418 753.805 770.192 786.579 802.966 40
50 819.353 835.740 852.127 868.514 884.901 901.288 917.675 934.062 950.449 966.837 50
.
60 983.224 999.611 1015.998 1032.385 1048.772 1065.159 1081.546 1097.933 1114.320 1130.707 60
De al
pt
70 1147.094 1163.481 1179.868 1196.255 1212.642 1229.030 1245.417 1261.804 1278.191 1294.578 70
80 1310.965 1327.352 1343.739 1360.126 1376.513 1392.900 1409.287 1425.674 1442.061 1458.448 80
g n
90 1474.835 1491.222 1507.610 1523.997 1540.384 1556.771 1573.158 1589.545 1605.932 1622.319 90
o
100 1638.706 1655.093 1671.480 1687.867 1704.254 1720.641 1737.028 1753.415 1769.802 1786.190 100
in ti
Cubic centimeters to cubic inches
cm3 cm3
et a
0 1 2 3 4 5 6 7 8 9
(cc) (cc)
n
3 3 3 3 3 3 3 3 3 3
in in in in in in in in in in
rk er
- - 0.0610 0.1220 0.1831 0.2441 0.3051 0.3661 0.4272 0.4882 0.5492 -

10 0.6102 0.6713 0.7323 0.7933 0.8543 0.9153 0.9764 1.0374 1.0984 1.1594 10
20 1.2205 1.2815 1.3425 1.4035 1.4646 1.5256 1.5866 1.6476 1.7086 1.7697 20
Ma t
30 1.8307 1.8917 1.9527 2.0138 2.0748 2.1358 2.1968 2.2579 2.3189 2.3799 30
In
40 2.4409 2.5019 2.5630 2.6240 2.6850 2.7460 2.8071 2.8681 2.9291 2.9901 40
50 3.0512 3.1122 3.1732 3.2342 3.2952 3.3563 3.4173 3.4783 3.5393 3.6004 50
60 3.6614 3.7224 3.7834 3.8444 3.9055 3.9665 4.0275 4.0885 4.1496 4.2106 60
70 4.2716 4.3326 4.3937 4.4547 4.5157 4.5767 4.6377 4.6988 4.7598 4.8208 70
80 4.8818 4.9429 5.0039 5.0649 5.1259 5.1870 5.2480 5.3090 5.3700 5.4310 80
90 5.4921 5.5531 5.6141 5.6751 5.7362 5.7972 5.8582 5.9192 5.9803 6.0413 90
100 6.1023 6.1633 6.2243 6.2854 6.3464 6.4074 6.4684 6.5295 6.5905 6.6515 100

U.S. Gallons to liters
U.S. U.S.
0 1 2 3 4 5 6 7 8 9
gal gal
liters liters liters liters liters liters liters liters liters liters
- - 3.7854 7.5709 11.3563 15.1417 18.9271 22.7126 26.4980 30.2834 34.0688 -
10 37.8543 41.6397 45.4251 49.2106 52.9960 56.7814 60.5668 64.3523 68.1377 71.9231 10
20 75.7085 79.4940 83.2794 87.0648 90.8502 94.6357 98.4211 102.2065 105.9920 109.7774 20
30 113.5628 117.3482 121.1337 124.9191 128.7045 132.4899 136.2754 140.0608 143.8462 147.6317 30
40 151.4171 155.2025 158.9879 162.7734 166.5588 170.3442 174.1296 177.9151 181.7005 185.4859 40
50 189.2714 193.0568 196.8422 200.6276 204.4131 208.1985 211.9839 215.7693 219.5548 223.3402 50
60 227.1256 230.9110 234.6965 238.4819 242.2673 246.0528 249.8382 253.6236 257.4090 261.1945 60
.
De al
70 264.9799 268.7653 272.5507 276.3362 280.1216 283.9070 287.6925 291.4779 295.2633 299.0487 70
pt
80 302.8342 306.6196 310.4050 314.1904 317.9759 321.7613 325.5467 329.3321 333.1176 336.9030 80
90 340.6884 344.4739 348.2593 352.0447 355.8301 359.6156 363.4010 367.1864 370.9718 374.7573 90
g n
100 378.5427 382.3281 386.1136 389.8990 393.6844 397.4698 401.2553 405.0407 408.8261 412.6115 100
o
in ti
Liters to U.S. Gallons

et a
liters 0 1 2 3 4 5 6 7 8 9 liters
n
gal gal gal gal gal gal gal gal gal gal
- - 0.2642 0.5283 0.7925 1.0567 1.3209 1.5850 1.8492 2.1134 2.3775 -
rk er
10 2.6417 2.9059 3.1701 3.4342 3.6984 3.9626 4.2268 4.4909 4.7551 5.0193 10
20 5.2834 5.5476 5.8118 6.0760 6.3401 6.6043 6.8685 7.1326 7.3968 7.6610 20
Ma t
30 7.9252 8.1893 8.4535 8.7177 8.9818 9.2460 9.5102 9.7744 10.0385 10.3027 30
40 10.5669 10.8311 11.0952 11.3594 11.6236 11.8877 12.1519 12.4161 12.6803 12.9444 40
In
50 13.2086 13.4728 13.7369 14.0011 14.2653 14.5295 14.7936 15.0578 15.3220 15.5861 50
60 15.8503 16.1145 16.3787 16.6428 16.9070 17.1712 17.4354 17.6995 17.9637 18.2279 60
70 18.4920 18.7562 19.0204 19.2846 19.5487 19.8129 20.0771 20.3412 20.6054 20.8696 70
80 21.1338 21.3979 21.6621 21.9263 22.1904 22.4546 22.7188 22.9830 23.2471 23.5113 80
90 23.7755 24.0397 24.3038 24.5680 24.8322 25.0963 25.3605 25.6247 25.8889 26.1530 90
100 26.4172 26.6814 26.9455 27.2097 27.4739 27.7381 28.0022 28.2664 28.5306 28.7947 100

U.K. Gallons to Liters
lmp lmp
0 1 2 3 4 5 6 7 8 9
gal gal
liters liters liters liters liters liters liters liters liters liters
- - 4.5459 9.0918 13.6377 18.1836 22.7295 27.2754 31.8213 36.3672 40.9131 -
10 45.4590 50.0049 54.5508 59.0967 63.6426 68.1885 72.7344 77.2803 81.8262 86.3721 10
20 90.9180 95.4639 100.0098 104.5557 109.1016 113.6475 118.1934 122.7393 127.2852 131.8311 20
30 136.3770 140.9229 145.4688 150.0147 154.5606 159.1065 163.6524 168.1983 172.7442 177.2901 30
40 181.8360 186.3819 190.9278 195.4737 200.0196 204.5655 209.1114 213.6573 218.2032 222.7491 40
50 227.2950 231.8409 236.3868 240.9327 245.4786 250.0245 254.5704 259.1163 263.6622 268.2081 50
60 272.7540 277.2999 281.8458 286.3917 290.9376 295.4835 300.0294 304.5753 309.1212 313.6671 60
.
De al
70 318.2130 322.7589 327.3048 331.8507 336.3966 340.9425 345.4884 350.0343 354.5802 359.1261 70
pt
80 363.6720 368.2179 372.7638 377.3097 381.8556 386.4015 390.9474 395.4933 400.0392 404.5851 80
90 409.1310 413.6769 418.2228 422.7687 427.3146 431.8605 436.4064 440.9523 445.4982 450.0441 90
g n
100 454.5900 459.1359 463.6818 468.2277 472.7736 477.3195 481.8654 486.4113 490.9572 495.5031 100
o
in ti
Liters to U.K. Gallons
liters 0 1 2 3 4 5 6 7 8 9 liters
et a
gal gal gal gal gal gal gal gal gal gal
n
- - 0.2200 0.4400 0.6599 0.8799 1.0999 1.3199 1.5399 1.7598 1.9798 -

rk er
10 2.1998 2.4198 2.6398 2.8597 3.0797 3.2997 3.5197 3.7397 3.9596 4.1796 10
20 4.3996 4.6196 4.8396 5.0595 5.2795 5.4995 5.7195 5.9395 6.1594 6.3794 20
30 6.5994 6.8194 7.0394 7.2593 7.4793 7.6993 7.9193 8.1393 8.3592 8.5792 30
Ma t
40 8.7992 9.0192 9.2392 9.4591 9.6791 9.8991 10.1191 10.3391 10.5590 10.7790 40
In
50 10.9990 11.2190 11.4390 11.6589 11.8789 12.0989 12.3189 12.5389 12.7588 12.9788 50
60 13.1988 13.4188 13.6388 13.8587 14.0787 14.2987 14.5187 14.7387 14.9586 15.1786 60
70 15.3986 15.6186 15.8386 16.0585 16.2785 16.4985 16.7185 16.9385 17.1584 17.3784 70
80 17.5984 17.8184 18.0384 18.2583 18.4783 18.6983 18.9183 19.1383 19.3582 19.5782 80
90 19.7982 20.0182 20.2382 20.4581 20.6781 20.8981 21.1181 21.3381 21.5580 21.7780 90
100 21.9980 22.2180 22.4380 22.6579 22.8779 23.0979 23.3179 23.5379 23.7578 23.9778 100

Weight
Pound to Kilogram
lbs. 0 1 2 3 4 5 6 7 8 9 lbs.
kg kg kg kg kg kg kg kg kg kg
- - 0.454 0.907 1.361 1.814 2.268 2.722 3.175 3.629 4.082 -
10 4.536 4.989 5.443 5.897 6.350 6.804 7.257 7.711 8.165 8.618 10
20 9.072 9.525 9.979 10.433 10.886 11.340 11.793 12.247 12.701 13.154 20
30 13.608 14.061 14.515 14.968 15.422 15.876 16.329 16.783 17.236 17.690 30
40 18.144 18.597 19.051 19.504 19.958 20.412 20.865 21.319 21.772 22.226 40
50 22.680 23.133 23.587 24.040 24.494 24.947 25.401 25.855 26.308 26.762 50
.
De al
60 27.215 27.669 28.123 28.576 29.030 29.483 29.937 30.391 30.844 31.298 60
pt
70 31.751 32.205 32.658 33.112 33.566 34.019 34.473 34.926 35.380 35.834 70
80 36.287 36.741 37.194 37.648 38.102 38.555 39.009 39.462 39.916 40.370 80
90 40.823
g n
41.277
o
41.730 42.184 42.637 43.091 43.545 43.998 44.452 44.905 90
100 45.359 45.813 46.266 46.720 47.173 47.627 48.081 48.534 48.988 49.441 100
in ti
Kilogram to Pound
et a
n
kg 0 1 2 3 4 5 6 7 8 9 kg
rk er
lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs.
- - 2.205 4.409 6.614 8.818 11.023 13.228 15.432 17.637 19.842 -
10 22.046 24.251 26.455 28.660 30.865 33.069 35.274 37.479 39.683 41.888 10
Ma t
20 44.092 46.297 48.502 50.706 52.911 55.116 57.320 59.525 61.729 63.934 20
In
30 66.139 68.343 70.548 72.752 74.957 77.162 79.366 81.571 83.776 85.980 30
40 88.185 90.389 92.594 94.799 97.003 99.208 101.413 103.617 105.822 108.026 40
50 110.231 112.436 114.640 116.845 119.049 121.254 123.459 125.663 127.868 130.073 50
60 132.277 134.482 136.686 138.891 141.096 143.300 145.505 147.710 149.914 152.119 60
70 154.323 156.528 158.733 160.937 163.142 165.347 167.551 169.756 171.960 174.165 70
80 176.370 178.574 180.779 182.983 185.188 187.393 189.597 191.802 194.007 196.211 80
90 198.416 200.620 202.825 205.030 207.234 209.439 211.644 213.848 216.053 218.257 90
100 220.462 222.667 224.871 227.076 229.280 231.485 233.690 235.894 238.099 240.304 100

Newton to Kilogram
N 0 10 20 30 40 50 60 70 80 90 N
kg kg kg kg kg kg kg kg kg kg
- - 1.020 2.039 3.059 4.079 5.099 6.118 7.138 8.158 9.177 -
100 10.197 11.217 12.237 13.256 14.276 15.296 16.316 17.335 18.355 19.375 100
200 20.394 21.414 22.434 23.454 24.473 25.493 26.513 27.532 28.552 29.572 200
300 30.592 31.611 32.631 33.651 34.670 35.690 36.710 37.730 38.749 39.769 300
400 40.789 41.809 42.828 43.848 44.868 45.887 46.907 47.927 48.947 49.966 400
500 50.986 52.006 53.025 54.045 55.065 56.085 57.104 58.124 59.144 60.163 500
600 61.183 62.203 63.223 64.242 65.262 66.282 67.302 68.321 69.341 70.361 600
.
De al
700 71.380 72.400 73.420 74.440 75.459 76.479 77.499 78.518 79.538 80.558 700
pt
800 81.578 82.597 83.617 84.637 85.656 86.676 87.696 88.716 89.735 90.755 800
900 91.775 92.795 93.814 94.834 95.854 96.873 97.893 98.913 99.933 100.952 900
g n
1000 101.972 102.992 104.011 105.031 106.051 107.071 108.090 109.110 110.130 111.149 1000
o
in ti
Kilogram to Newton
kg 0 1 2 3 4 5 6 7 8 9 kg
et a
N N N N N N N N N N
n
- - 9.81 19.61 29.42 39.23 49.03 58.84 68.65 78.45 88.26 -

rk er
10 98.07 107.87 117.68 127.49 137.29 147.10 156.91 166.71 176.52 186.33 10
20 196.13 205.94 215.75 225.55 235.36 245.17 254.97 264.78 274.59 284.39 20
30 294.20 304.01 313.81 323.62 333.43 343.23 353.04 362.85 372.65 382.46 30
Ma t
40 392.27 402.07 411.88 421.69 431.49 441.30 451.11 460.91 470.72 480.53 40
In
50 490.34 500.14 509.95 519.76 529.56 539.37 549.18 558.98 568.79 578.60 50
60 588.40 598.21 608.02 617.82 627.63 637.44 647.24 657.05 666.86 676.66 60
70 686.47 696.28 706.08 715.89 725.70 735.50 745.31 755.12 764.92 774.73 70
80 784.54 794.34 804.15 813.96 823.76 833.57 843.38 853.18 862.99 872.80 80
90 882.60 892.41 902.22 912.02 921.83 931.64 941.44 951.25 961.06 970.86 90
100 980.67 990.48 1000.28 1010.09 1019.90 1029.70 1039.51 1049.32 1059.12 1068.93 100

Pressure
Lb/in² to Kg/cm²
lb/
0 1 2 3 4 5 6 7 8 9 lb/in2
in2
(psi) kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 (psi)
- - 0.0703 0.1406 0.2109 0.2812 0.3515 0.4218 0.4921 0.5625 0.6328 -
10 0.7031 0.7734 0.8437 0.9140 0.9843 1.0546 1.1249 1.1952 1.2655 1.3358 10
20 1.4061 1.4764 1.5468 1.6171 1.6874 1.7577 1.8280 1.8983 1.9686 2.0389 20
30 2.1092 2.1795 2.2498 2.3201 2.3904 2.4607 2.5311 2.6014 2.6717 2.7420 30
40 2.8123 2.8826 2.9529 3.0232 3.0935 3.1638 3.2341 3.3044 3.3747 3.4450 40
50 3.5154 3.5857 3.6560 3.7263 3.7966 3.8669 3.9372 4.0075 4.0778 4.1481 50
.
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60 4.2184 4.2887 4.3590 4.4293 4.4996 4.5700 4.6403 4.7106 4.7809 4.8512 60
pt
70 4.9215 4.9918 5.0621 5.1324 5.2027 5.2730 5.3433 5.4136 5.4839 5.5543 70
80 5.6246 5.6949 5.7652 5.8355 5.9058 5.9761 6.0464 6.1167 6.1870 6.2573 80
g n
90 6.3276 6.3979 6.4682 6.5386 6.6089 6.6792 6.7495 6.8198 6.8901 6.9604 90
o
100 7.0307 7.1010 7.1713 7.2416 7.3119 7.3822 7.4525 7.5228 7.5932 7.6635 100
in ti
Kg/cm² to Lb/in²
et a
kg/
0 1 2 3 4 5 6 7 8 9 kg/cm2
cm2
n
lb/in2 lb/in2 lb/in2 lb/in2 lb/in2 lb/in2 lb/in2 lb/in2 lb/in2 lb/in2
rk er
(psi) (psi) (psi) (psi) (psi) (psi) (psi) (psi) (psi) (psi)
- - 14.22 28.45 42.67 56.89 71.12 85.34 99.56 113.78 128.01 -
10 142.23 156.45 170.68 184.90 199.12 213.35 227.57 241.79 256.01 270.24 10
Ma t
20 284.46 298.68 312.91 327.13 341.35 355.58 369.80 384.02 398.24 412.47 20
In
30 426.69 440.91 455.14 469.36 483.58 497.81 512.03 526.25 540.47 554.70 30
40 568.92 583.14 597.37 611.59 625.81 640.04 654.26 668.48 682.70 696.93 40
50 711.15 725.37 739.60 753.82 768.04 782.27 796.49 810.71 824.93 839.16 50
60 853.38 867.60 881.83 896.05 910.27 924.50 938.72 952.94 967.16 981.39 60
70 995.61 1009.83 1024.06 1038.28 1052.50 1066.73 1080.95 1095.17 1109.39 1123.62 70
80 1137.84 1152.06 1166.29 1180.51 1194.73 1208.96 1223.18 1237.40 1251.62 1265.85 80
90 1280.07 1294.29 1308.52 1322.74 1336.96 1351.19 1365.41 1379.63 1393.85 1408.08 90
100 1422.30 1436.52 1450.75 1464.97 1479.19 1493.42 1507.64 1521.86 1536.08 1550.31 100

Kg/cm² to Kpa
kg/ kg/
0 1 2 3 4 5 6 7 8 9
cm2 cm2
Kpa Kpa Kpa Kpa Kpa Kpa Kpa Kpa Kpa Kpa
- - 98.1 196.1 294.2 392.3 490.3 588.4 686.5 784.5 882.6 -
10 980.7 1078.7 1176.8 1274.9 1372.9 1471.0 1569.1 1667.1 1765.2 1863.3 10
20 1961.3 2059.4 2157.5 2255.5 2353.6 2451.7 2549.7 2647.8 2745.9 2843.9 20
30 2942.0 3040.1 3138.1 3236.2 3334.3 3432.3 3530.4 3628.5 3726.5 3824.6 30
40 3922.7 4020.7 4118.8 4216.9 4314.9 4413.0 4511.1 4609.1 4707.2 4805.3 40
50 4903.4 5001.4 5099.5 5197.6 5295.6 5393.7 5491.8 5589.8 5687.9 5786.0 50
60 5884.0 5982.1 6080.2 6178.2 6276.3 6374.4 6472.4 6570.5 6668.6 6766.6 60
.
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70 6864.7 6962.8 7060.8 7158.9 7257.0 7355.0 7453.1 7551.2 7649.2 7747.3 70
pt
80 7845.4 7943.4 8041.5 8139.6 8237.6 8335.7 8433.8 8531.8 8629.9 8728.0 80
90 8826.0 8924.1 9022.2 9120.2 9218.3 9316.4 9414.4 9512.5 9610.6 9708.6 90
g n
100 9806.7 9904.8 10002.8 10100.9 10199.0 10297.0 10395.1 10493.2 10591.2 10689.3 100
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Kpa to Kg/cm²
et a
Kpa 0 100 200 300 400 500 600 700 800 900 Kpa
kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2
n
- - 1.020 2.039 3.059 4.079 5.099 6.118 7.138 8.158 9.177 -

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1000 10.197 11.217 12.237 13.256 14.276 15.296 16.316 17.335 18.355 19.375 1000
2000 20.394 21.414 22.434 23.454 24.473 25.493 26.513 27.532 28.552 29.572 2000
Ma t
3000 30.592 31.611 32.631 33.651 34.670 35.690 36.710 37.730 38.749 39.769 3000
4000 40.789 41.809 42.828 43.848 44.868 45.887 46.907 47.927 48.947 49.966 4000
In
5000 50.986 52.006 53.025 54.045 55.065 56.085 57.104 58.124 59.144 60.163 5000
6000 61.183 62.203 63.223 64.242 65.262 66.282 67.302 68.321 69.341 70.361 6000
7000 71.380 72.400 73.420 74.440 75.459 76.479 77.499 78.518 79.538 80.558 7000
8000 81.578 82.597 83.617 84.637 85.656 86.676 87.696 88.716 89.735 90.755 8000
9000 91.775 92.795 93.814 94.834 95.854 96.873 97.893 98.913 99.933 100.952 9000
10000 101.972 102.992 104.011 105.031 106.051 107.071 108.090 109.110 110.130 111.149 10000

Torque
Ft·lbs to Kg·m
ft·lbs 0 1 2 3 4 5 6 7 8 9 ft·lbs
kg·m kg·m kg·m kg·m kg·m kg·m kg·m kg·m kg·m kg·m
- - 0.138 0.277 0.415 0.553 0.691 0.830 0.968 1.106 1.244 -
10 1.383 1.521 1.659 1.797 1.936 2.074 2.212 2.350 2.489 2.627 10
20 2.765 2.903 3.042 3.180 3.318 3.457 3.595 3.733 3.871 4.010 20
30 4.148 4.286 4.424 4.563 4.701 4.839 4.977 5.116 5.254 5.392 30
40 5.530 5.669 5.807 5.945 6.083 6.222 6.360 6.498 6.636 6.775 40
50 6.913 7.051 7.190 7.328 7.466 7.604 7.743 7.881 8.019 8.157 50
.
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60 8.296 8.434 8.572 8.710 8.849 8.987 9.125 9.263 9.402 9.540 60
pt
70 9.678 9.816 9.955 10.093 10.231 10.370 10.508 10.646 10.784 10.923 70
80 11.061 11.199 11.337 11.476 11.614 11.752 11.890 12.029 12.167 12.305 80
g n
90 12.443 12.582 12.720 12.858 12.996 13.135 13.273 13.411 13.549 13.688 90
o
100 13.826 13.964 14.103 14.241 14.379 14.517 14.656 14.794 14.932 15.070 100
in ti
Kg·m to Ft·lbs
et a
kg·m 0 1 2 3 4 5 6 7 8 9 kg·m
n
ft·lbs ft·lbs ft·lbs ft·lbs ft·lbs ft·lbs ft·lbs ft·lbs ft·lbs ft·lbs
rk er
- - 7.23 14.47 21.70 28.93 36.17 43.40 50.63 57.86 65.10 -

10 72.33 79.56 86.80 94.03 101.26 108.50 115.73 122.96 130.19 137.43 10
20 144.66 151.89 159.13 166.36 173.59 180.83 188.06 195.29 202.52 209.76 20
Ma t
30 216.99 224.22 231.46 238.69 245.92 253.16 260.39 267.62 274.85 282.09 30
In
40 289.32 296.55 303.79 311.02 318.25 325.49 332.72 339.95 347.18 354.42 40
50 361.65 368.88 376.12 383.35 390.58 397.82 405.05 412.28 419.51 426.75 50
60 433.98 441.21 448.45 455.68 462.91 470.15 477.38 484.61 491.84 499.08 60
70 506.31 513.54 520.78 528.01 535.24 542.48 549.71 556.94 564.17 571.41 70
80 578.64 585.87 593.11 600.34 607.57 614.81 622.04 629.27 636.50 643.74 80
90 650.97 658.20 665.44 672.67 679.90 687.14 694.37 701.60 708.83 716.07 90
100 723.30 730.53 737.77 745.00 752.23 759.47 766.70 773.93 781.16 788.40 100

Kg·m to N·m
kg·m 0 1 2 3 4 5 6 7 8 9 kg·m
N·m N·m N·m N·m N·m N·m N·m N·m N·m N·m
- - 9.81 19.61 29.42 39.23 49.03 58.84 68.65 78.45 88.26 -
10 98.07 107.87 117.68 127.49 137.29 147.10 156.91 166.71 176.52 186.33 10
20 196.13 205.94 215.75 225.55 235.36 245.17 254.97 264.78 274.59 284.39 20
30 294.20 304.01 313.81 323.62 333.43 343.23 353.04 362.85 372.65 382.46 30
40 392.27 402.07 411.88 421.69 431.49 441.30 451.11 460.91 470.72 480.53 40
50 490.34 500.14 509.95 519.76 529.56 539.37 549.18 558.98 568.79 578.60 50
60 588.40 598.21 608.02 617.82 627.63 637.44 647.24 657.05 666.86 676.66 60
.
De al
70 686.47 696.28 706.08 715.89 725.70 735.50 745.31 755.12 764.92 774.73 70
pt
80 784.54 794.34 804.15 813.96 823.76 833.57 843.38 853.18 862.99 872.80 80
90 882.60 892.41 902.22 912.02 921.83 931.64 941.44 951.25 961.06 970.86 90
100 980.67
g n
990.48 1000.28 1010.09 1019.90 1029.70 1039.51 1049.32 1059.12 1068.93 100
o
in ti
N·m to Kg·m
N·m 0 10 20 30 40 50 60 70 80 90 N·m
et a
kg·m kg·m kg·m kg·m kg·m kg·m kg·m kg·m kg·m kg·m
n
- - 1.020 2.039 3.059 4.079 5.099 6.118 7.138 8.158 9.177 -

rk er
100 10.197 11.217 12.237 13.256 14.276 15.296 16.316 17.335 18.355 19.375 10
200 20.394 21.414 22.434 23.454 24.473 25.493 26.513 27.532 28.552 29.572 20
300 30.592 31.611 32.631 33.651 34.670 35.690 36.710 37.730 38.749 39.769 30
Ma t
400 40.789 41.809 42.828 43.848 44.868 45.887 46.907 47.927 48.947 49.966 40
In
500 50.986 52.006 53.025 54.045 55.065 56.085 57.104 58.124 59.144 60.163 50
600 61.183 62.203 63.223 64.242 65.262 66.282 67.302 68.321 69.341 70.361 60
700 71.380 72.400 73.420 74.440 75.459 76.479 77.499 78.518 79.538 80.558 70
800 81.578 82.597 83.617 84.637 85.656 86.676 87.696 88.716 89.735 90.755 80
900 91.775 92.795 93.814 94.834 95.854 96.873 97.893 98.913 99.933 100.952 90
1000 101.972 102.992 104.011 105.031 106.051 107.071 108.090 109.110 110.130 111.149 100

Temperature
A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading
(or vice versa) is to enter the following table in the center (boldface column) of figures. These fig-
ures refer to the temperature in either Fahrenheit or Centigrade degrees.
To convert from Fahrenheit to Centigrade degrees, consider the center column as Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
To convert from Centigrade to Fahrenheit degrees, consider the center column as Centigrade val-
ues, and read the corresponding Fahrenheit temperature on the right.
.
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1°C = 33.8°F
°C °F °C °F °C °F °C °F
-40.0 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -2
-20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
.
De al
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
pt
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
g n
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
o
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
in ti
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0

-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
et a
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4

n
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2

rk er
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
-19.4 -3 26.6 0.0 32 89.6 19.4 67 152.6 43.3 110 230.0
Ma t
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0

-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
In
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.8 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

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SY195/205/215/225C9 Crawler Hydraulic Excavator Shop Safety
Shop Safety
.
2 Shop Safety
De al
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2.1 Hazard Alert Information .......................................................................................... 2-3
2.2 General Shop Safety ............................................................................................... 2-6
g n
2.2.1 Rules and shop behavior ............................................................................... 2-7
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2.2.2 Housekeeping ................................................................................................ 2-7
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2.2.3 Shop Liquids Storage..................................................................................... 2-8

2.2.4 Cleaning Parts ............................................................................................... 2-8
2.2.5 Jacking Up the Machine................................................................................. 2-9
et a
2.2.6 Electrical Dangers .......................................................................................... 2-9

n
2.2.7 Removing Attachments ................................................................................ 2-10

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2.2.8 Cleaning the Machine .................................................................................. 2-10

2.2.9 Using the Correct Tools................................................................................ 2-10
2.2.10 Hoisting a Load ...........................................................................................2-11
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2.2.11 Appropriate Working Apparel ..................................................................... 2-12

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2.2.12 Safety Partners .......................................................................................... 2-12

2.2.13 Two people when engine running .............................................................. 2-13
2.2.14 Driving Pins ................................................................................................ 2-13
2.2.15 Aligning Parts or Components ................................................................... 2-14
2.2.16 Fire Extinguisher and Emergency Exits ..................................................... 2-14
2.2.17 Personal Protective Equipment.................................................................. 2-14
2.2.18 Running the Machine ................................................................................. 2-15
2.2.19 Accumulator ............................................................................................... 2-16
2.2.20 Adding Fluids to a System ......................................................................... 2-16
2.2.21 Track Recoil Springs .................................................................................. 2-17
2.2.22 High-Pressure Fluid Lines.......................................................................... 2-17
2.2.23 Safe Work Preparations ............................................................................. 2-18
2.2.24 Mounting and Dismounting ........................................................................ 2-19

Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator
2.2.25 Battery Hazards ......................................................................................... 2-20

2.2.26 Jump-Start Safety ...................................................................................... 2-21
2.2.27 Disconnecting the System Power .............................................................. 2-21
2.2.28 Lockout/tagout ........................................................................................... 2-22
2.2.29 Sequence of Procedures ........................................................................... 2-22
2.2.30 Chemical hazard ........................................................................................ 2-24
2.2.31 Material Safety Data Sheets (MSDS) ........................................................ 2-24
2.3 Precautions for sling work and giving signals ........................................................ 2-25
.
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WARNING
jury or death.

2 SHOP SAFETY
2.1 Hazard Alert Information

Most accidents are usually caused by the fail-
ure to follow fundamental repair procedures
and safety rules for the system under repair.
To avoid accidents it is important to read and
understand all information outlined in this
manual before performing repairs on the ma-
chine system.
The following (ANSI/ISO) signal words are
.
De al
used to inform you that there is a potentially
pt
hazardous situation that may lead to damage,
personal injury or even death. In this manual,
g n
on the machine, part or component decals and
different signal words are used to express the
o
potential level of a hazard.
in ti
DANGER
et a
Indicates an imminent hazard which WILL

n
result in serious injury or death if message

is ignored.
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WARNING
Ma t
Indicates a potentially hazardous situation

In
which COULD result in serious injury or

death if message is ignored.
CAUTION
Indicates a potentially hazardous situation
which COULD RESULT IN MINOR OR MA-
JOR INJURY if message is ignored.
NOTICE
Indicates THE MACHINE MAY BE DAM-
AGED if improperly operated or main-
tained.

This is to alert the user of a hazard. It is

usually used in a graphic.
This symbol is used in a graphic to alert

the user to not do something.
SANY cannot predict every circumstance that

might involve a potential hazard in a repair of
the machine. Therefore the safety message in
this manual and on the machine may not in-
clude all possible safety precautions.
If any procedures or actions not specified, rec-
.
ommended or allowed in this manual are used,
De al
you must be sure that you and others can
pt
perform such procedures and actions safely
and without damaging the machine. If you are
g n
unsure about the safety of some procedures,
o
contact your SANY representative.
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WARNING
● Improper repair procedures on this ma-
chine can be hazardous and could re-
sult in serious injury or even death.
● All personnel involved with the repair

of this machine must read this manual
thoroughly before performing any pro-
cedures on this equipment.
● Some actions involved in the operation

or repair of this machine could cause
a serious accident if they are not per-
.
formed in the manner described in this
De al
manual.
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● All precautions outlined in this manual
g n
apply only to intended repair proce-
dures of the machine or system. If you
o
perform any repairs not specifically pro-
in ti
hibited, you must be sure that it is safe

for you and others. In no event should
you or others engage in prohibited uses
et a
or actions as described in this manual.

n
● SANY delivers machines that comply

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with all applicable regulations and

standards of the country to which the
machines have been shipped. If this
machine has been purchased in another
Ma t
country or purchased from someone

In
in another country, it may lack certain

safety features and specifications that
are necessary for use in your country.
If there is any question about whether
your product complies with the appli-
cable standards and regulations of your
country, contact your SANY representa-
tive before performing repairs on this
machine.

2.2 General Shop Safety
It's important to establish good shop safety

rules for everyone who enters or uses the
shop area. Implementing shop safety rules
will keep employees safe and provide the
most productive environment for working or
learning. Post rules where they can clearly be
viewed at all times. If necessary, provide shop
personnel with a written copy of the rules and
discuss any questions or confusion with them.
Always keep in mind, shop safety is NOT

something to be studied at the start of a proj-
.
De al
ect and then forgotten; most accidents are
pt
caused by carelessness, being in a hurry or by
simply disreguarding safety rules. Remember
g n
this, if you are DILIGENT and follow instruc-
tions outlined in this shop manual with care,
o
repair operations can be safe and enjoyable.
in ti
Safe work practices, should become a force of

habit.
et a
n
WARNING
rk er
● Mistakes in operation are extremely

hazardous. Read the Safety, Operation
& Maintenance Manual that came with
Ma t
the machine carefully before operating

In
the machine. Failure to follow this alert

could result in serious injury or death.

2.2.1 Rules and shop behavior
● Study all shop rules relating to the proce-

dure carefully and constantly apply them.
When in doubt about any task, get help!
DO NOT take chances.
● Know your job. It is foolish, and often di-

sastrous, to make repairs to a machine
without first receiving proper instructions.
Always use the shop manual when per-
forming any repair tasks. Get additional
help if you are NOT sure what must be
done or how a task should be performed.
.
De al
pt
● The shop is a place to work, not play. It is
NOT a place for “horseplay”. A “joker” in a
g n
repair shop is a “walking hazard” to every-
one. Daydreaming or socializing on the job CA13082101
o
also increases your chances of injury.
in ti
● If you must smoke, smoke only in the area

provided for smoking. Never smoke while
on the shop floor or work area.
et a
n
2.2.2 Housekeeping
rk er
● Oils, grease, fuel, antifreeze or any fluid

spills should be mopped up immediately.
These items pose a serious slip hazard.
Ma t
Regardless of who was responsible for the

spill, it is your job as a shop employee to
In
secure and clean up the spill area.
● Keep the shop clean. Scrap or old parts

should be disposed of properly. Never al-
low them to remain on the bench or shop
floor.
● All equipment and tools must be put back

in their proper storage areas after each
use. It's imperative that you do not let a
shop become cluttered and disorganized in
order to prevent accidents. CA13082102
● Always keep in mind, proper house clean-

ing is vital for a safe and pleasant work en-
vironment.

2.2.3 Shop Liquids Storage
● Liquids, cleaning solvents or machine flu-

ids should be properly stored in an area
away from work locations. These storage
areas should be ventilated to an outdoor
location to avoid any vapor accumulation
in a confined shop area. Follow all OSHA
regulations regarding fluid storage.
● Never leave open containers of liquids sit-

ting around. These could spill or catch fire.
Always read the container label for infor-
mation on storage and handling of the liq-
.
De al
uids.
pt
● Never store liquids in containers that are
not properly labeled for that liquid. Confu-
g n
sion could result in equipment damage, fire
o
CA13082103
or an unexpected explosion.
in ti
● Never smoke or bring open flames around

liquids, doing so could result in an unex-
pected fire or explosion.
et a
● Never handle liquids without using person-

n
al protective equipment. Treat all liquids

with caution.
rk er
Ma t
In
2.2.4 Cleaning Parts
Never use gasoline, diesel fuel or similar flam-

mable liquids to clean parts. Always use ap-
proved non-flammable solvents to clean parts.
Failure to do so could result in explosion or
fire.
CA13082104

2.2.5 Jacking Up the Machine
● If you will be working under the machine

always use approved jack stands that will
support the weight of the machine you are
working on.
● Never rely on the hydraulics of the ma-

chine or a hydraulic jack to support the
machine during repairs.
● Always lower the work equipment to the

ground and check the stability of the ma-
chine before going under the machine. CZ335-1102078
.
De al
pt
g no
2.2.6 Electrical Dangers
in ti
● When testing electrical circuits, always be

aware of what you will be checking in these
systems. High voltage or high amp circuits
et a
could damage your equipment or cause a

spark, explosion or possible fire.
n
● Before performing any repairs or testing on

rk er
an electrical system be sure of the system

voltage dangers. Always check the circuit
to be sure it is off before performing any
Ma t
repairs.
In
● When working around flammable liquids or

explosive systems, use only approved anti-
explosion proof work lamps. Non-approved
work lamps can cause an explosion or fire.
CA13082105

2.2.7 Removing Attachments
● If you will be removing large heavy attach-

ments from the machine, always be sure to
use the correct lifting equipment rated for
the capacity of the load you will be lifting.
● After the attachment or part has been

removed, store it where it cannot fall or
move. Always be sure what you are stor-
ing is sitting stable on a stable surface and
clear of all walkways or fire exits.
CA13082106
.
De al
pt
2.2.8 Cleaning the Machine
● Always use high-pressure hot water and

g n
mild, nonflammable grease-cutting soaps
o
or cleaning agents to clean the machine
parts. Never use flammable or caustic
in ti
cleaning agents.
● Never use high-pressure steam cleaners

et a
to clean the machine. Steam cleaners will

damage the paint, hoses or electrical sys-
n
tem.
rk er
● Never pressure-wash or flood the inside of CA13082107

an operator cab. This will damage sensi-
tive electrical components.
Ma t
In
2.2.9 Using the Correct Tools
● Always use the proper authorized tools for

the job. Using tools that are not authorized,
incorrect for the job, defective or damaged
could cause serious injury.
● Keep all tools in good condition, learn the

correct way to use them.

● Before starting the work, thoroughly check

the tools, machine, forklift, crane, service
car, etc.
● Keep your tools clean, and when the job is

complete, take inventory of the tools you
were using to be sure no tools were left in
the machine.
● Always put shop tools back in there proper

storage location when finished.
● If welding repairs are needed, always have

a trained, experienced or certified welder
carry out the work.
.
De al
pt
ZX215-1000033
g no
2.2.10 Hoisting a Load
in ti
If you will be lifting parts or components that

weigh more than 35 lbs (16 kg), it is important
et a
to follow some basic rules.

n
● Always use the appropriate lifting equip-

ment such as hoist, crane, forklift etc. to
rk er
handle a loads if possible.
● Be sure the lifting equipment is in good

Ma t
condition and rated for the load you are

about to lift.
In
● If straps are to be used, ensure they are in

good condition and rated for the load to be
CA13082108
lifted with them.
● If you must lift the load by hand, keep your

back straight and parallel with the load,
and lift the load using your leg muscles to
avoid back injuries. Always ask for a lifting
assistant.

2.2.11 Appropriate Working Apparel
Improper or loose clothing, casual dress cloth-

ing, jewelry, incorrect shoes or long hair can
result in possible injury.
Make a list of the types of clothing that are not

allowed in the shop area. Go over the list with
personnel before they start a job.
.
De al
pt
CA13082109
g no
2.2.12 Safety Partners
in ti
No one should be allowed to perform work

operations in any shop alone. It should be a
general shop safety rule for a minimum of two
et a
people in the shop area at all times when work

n
procedures are performed. A person alone in

the shop might not be able to get emergency
rk er
help in the event of a shop accident.
When working together always maintain clear

Ma t
contact with each other at all times to avoid

the occurrence of unexpected incidents.
In
CA13082110
When carrying out any operation with two or
more workers, always agree on the operating
procedures and signals before starting.

2.2.13 Two people when engine run-

ning
In order to prevent injury, do not perform the

service while the engine is running. If the ser-
vice must be performed while the engine is
running, operate only when two people are on
the spot and follow the regulations below:
● Always have one operator sit on the op-

eration seat and be ready to turn off the
engine at any time. All the operators must
keep in touch with each other.
.
● Set the safety lock control lever to the lock
De al
position.
pt
● Do not touch any control lever. If some
g n
control lever must be operated, send signal
to other people and warn them to transfer
o
to safe place quickly.
in ti
● Do not drop or insert the tools and other

objects into the fan or fan belt, or the parts
will be broken or thrown out.
et a
n
rk er
2.2.14 Driving Pins
When using a hammer to drive pins, metal

Ma t
particles may fly off. This may lead to serious

In
eye injuries. Always do the following:
● Always wear a face shield or goggles when

striking a metal object with a metal ham-
mer.
● Before performing any of these proce-

dures, be sure all personnel are clear of
your work area.
● If possible, avoid using a steel hammer to

CZ335-1102069
drive a component or pins in place. Dam-
age to the component may result. Always
use a soft or non-ferrous hammer to drive
a component or a pin.

2.2.15 Aligning Parts or Components
● Be careful when installing or aligning parts

or components.
● Avoid using your fingers or hands to posi-

tion holes or part mating surfaces, serious
injury could result if your hand or fingers
should get ought between the surfaces.
● Always use tools to align a part or compo-

nent to avoid any finger or hand injuries.
CA13082111
.
2.2.16 Fire Extinguisher and Emer-
De al
gency Exits
pt
● It is important to know where all emergen-
g n
cy exits and fire extinguishing equipment
o
are located if a fire should occur in the
shop.
in ti
● Before preparing for work, take time and

walk around the shop to make a mental
et a
note of where all exits and fire equipment

are located. If you are performing repairs
n
in the field, always have a fire extinguisher

rk er
handy and within reach.

CA13082112
● If you do not know how to use a fire extin-
guisher contact someone who can instruct
Ma t
you in the proper use of this equipment.

In
2.2.17 Personal Protective Equipment
If your shop specifies the use of safety equip-

ment, OSHA requires this equipment to be
used when on the shop floor or in the area
where this equipment is required.
Never allow personnel in the shop area with-

out the proper personnel protective equipment
even for a moment.
Always keep personnel protective equipment

in good condition and replace them as re-
quired.
CZ335-1102002

2.2.18 Running the Machine
Run the machine during repair procedures

ONLY if directed to do so in this shop manual.
If the machine must be run when making re-
pairs, it is important to follow some basic safe-
ty rules.
● Always be aware of rotating components.
● During repair operations while the engine

is running, one worker must remain in the
operator seat of the machine with clear
contact between the person performing the
.
repairs on the machine at all times.
De al
CZ335-1102077
pt
● If equipped, all lock levers must be in the
LOCK position or the parking brake must
g n
be in the PARK position.
o
● The person in the cab must never touch
any controls. If a control lever must be op-
in ti
erated, always maintain a clear view to the

person doing the repair and signal them
when you are about to move the control le-
et a
ver.
n
● Be aware of hot surfaces. During running

rk er
operations, most surfaces will be hot, and

some surfaces will be extremely hot. If
necessary, use personnel protective equip-
Ma t
ment when working around high tempera-

CZ335-1102012
ture surfaces.
In
● Keep in mind that during running opera-

tions, hydraulic systems, cooling systems
and fuel systems will be under extremely
high pressure and at high temperatures.
● Always use caution when working on or

near these systems.
CA13082113

2.2.19 Accumulator
If the machine is equipped with an accumula-

tor charged with high-pressure nitrogen gas, it
is important to follow these basic precautions.
● Do not disassemble the accumulator.
● Never expose the accumulator to high heat

or open flames.
● Never weld on the accumulator.
● Never drill or cut on the accumulator.
.
● Never strike the accumulator.
De al
CZ335-1102085
pt
● Use only nitrogen gas to charge the ac-
cumulator. Unapproved gases could be
g n
explosive.
o
in ti
2.2.20 Adding Fluids to a System

et a
If it should be necessary to add fluids to a

n
system during running operations, always be

rk er
aware that these systems may be hot and un-

der high pressure.
Before adding fluids, shut the machine down

Ma t
and allow the systems to cool down to outdoor

In
ambient temperatures before removing any

caps. Failure to do so may result in serious
burns or a sudden loss of fluid.
CA13082114

2.2.21 Track Recoil Springs
If you are making repairs to a machine

equipped with tracks, always be aware of the
dangers involved with track recoil springs. This
spring is under extreme pressure at all times.
If it is disassembled by mistake, the spring
may fly out and cause serious injury or death.
Be careful when removing or installing tracks

on track-type machines. When removing the
master track link the track system may sepa-
rate suddenly and cause possible injury.
.
Always stand clear of the track travel path
De al
CZ335-1102081
when separating the master link section of the
pt
track. g no
2.2.22 High-Pressure Fluid Lines
in ti
Always keep in mind that these systems are

under high pressure. When inspecting or re-
placing piping or hoses, always check to be
et a
sure the pressure in the system has been

n
relieved before proceeding. Working on a sys-

tem still under pressure could lead to serious
rk er
injury, always do as follows:
● If you will be removing a line or component

Ma t
with fluid in the system, always cap and

seal the opening to avoid leakage or sys-
In
tem contamination.
● Never carry out inspections or replace

items while the system is under pressure.
● Never use any part of your body to check

or feel for leaks. Always wear safety
glasses and leather gloves when checking
for leaks and use a piece of wood or card-
board when checking for leaks from small
holes.
● If high pressure fluids should penetrate

your skin or get into your eyes, seek medi- CZ335-1102082
cal attention immediately.

2.2.23 Safe Work Preparations
Before starting any repairs, be sure the ma-

chine is sitting on a level stable surface.
Lower all the work equipment to a safe and

stable position on the ground. Turn the engine
OFF and neutralize the work equipment con-
trols by rotating them to the left and right (joy-
stick control) or moving them back and forth
(lever control). This function will relieve system
pressure.
Block the tracks (if equipped) or wheels (if CA13082115
.
equipped) with chocks to prevent the machine
De al
from moving.
pt
If equipped, set the hydraulic lock lever in the
g n
LOCKED position. If equipped, set the parking
brake in the PARK position.
o
Be sure all personnel and equipment is clear
in ti
of your work area and you can be seen by all

working personnel especially if performing re-
pairs in the field.
et a
n
rk er
Ma t
In

2.2.24 Mounting and Dismounting
It is important to follow these procedures when

mounting or dismounting the equipment:
● Use all hand-holds and step plates on your

equipment.
● Never jump off or onto the equipment.
● Wipe off any oil, grease, or mud from your

shoes, rails, steps or platforms before get-
ting on the equipment; always keep these
areas clean and in good condition.
CA13031506
.
● Never get on or off moving equipment.
De al
These actions may lead to serious injury.
pt
Always bring the equipment to a full stop
and turn the engine OFF.
g no
● When getting on or off the equipment,
always face the equipment and maintain
in ti
a three-point contact (both feet and one

hand or one foot and both hands) with the
handrails, steps and platforms to ensure
et a
that you support yourself correctly.

n
● Never climb on areas of the machine that

rk er
are not designated walk areas.
● Never climb on or off the machine with

tools, parts or similar objects in your
Ma t
hands.
In
● Never use machine controls or non-spec-

ified points on the equipment to get on or
off the machine.
● Use all hand-holds when on the machine.

CA13082116

2.2.25 Battery Hazards
Working around batteries always poses a haz-

ard, especially if the battery has been in ser-
vice for a long period of time.
Listed below are some basic precautions to

be aware of when servicing or working around
batteries.
● Always wear personal protective equip-

ment when working around batteries.
● Battery gasses are extremely explosive.

CZ335-1102061
When opening a battery compartment, al-
.
De al
ways allow ample time for the gasses to
pt
escape before servicing the battery.
g n
● When working with batteries, always work
o
in a wellventilated area.
in ti
● If the battery is corroded, flush the area

with a baking soda and warm water mix.
et a
n
rk er
Ma t
CZ335-1102062
In
● If battery acid should get on your skin or in

your eyes, flush the area immediately with
fresh water and seek medical attention.
CZ335-1102083

2.2.26 Jump-Start Safety
When using jumper cables to start the ma-

chine, connect the positive (+) jumper first,
then the negative (-) jumper to a remote loca-
tion on the chassis away from the battery.
CAUTION
Never use a welder or a machine with a
higher voltage system to jump-start the
machine. Doing so may damage the ma-
chine’s electrical system or cause an unex- CA13082117
.
De al
pected explosion or fire resulting in minor
pt
or major injury.
g n
2.2.27 Disconnecting the System
o
Power
in ti
Before starting any repair operations, remove

the battery leads from the battery or set the
main disconnect on the machine in the OFF
et a
position.
n
For the location of the machine main electri-

cal disconnect switch, refer to the machines
rk er
Safety, Operation & Maintenance Manual for

location and procedures.
Ma t
If the battery must be disconnected, remove

the negative (-) terminal clamp first then re-
In
move the positive (+) clamp last.
When reconnecting the battery, be sure every

electrical system switch is in the OFF position,
connect the positive clamp (+) first, then the
negative clamp(-) last.
CA13082118

2.2.28 Lockout/tagout
Due to the size and complexity of this ma-

chine, Lockout and Tagout procedures may
be required by your company to ensure the
safety of yourself and others involved in the
repair process of the machine. While work
is in progress, all power sources must be
disabled, locked and tagged with a warning
label. Lockout/Tagout procedure establishes
the minimum requirements used to isolate all
power sources from potentially hazardous en-
ergy, and to ensure that the machine is “locked
.
out and tagged out” before anyone performs
De al
repairs on the machine.
pt
g no
2.2.29 Sequence of Procedures
in ti
Only authorized employees performing repairs

on the machine shall perform Lockout/Tagout
in accordance with this procedure listed below.
et a
DA
If the employee performing repairs to the ma- NG
ER
n
chine is issued DO
OP NO
rk er
a lock and key, the employee shall not share ER T

AT
the lock or key with other employees until all E
repair procedures are complete and the ma-
Ma t
chine is ready to put back into service.

In
The following steps shall be performed in the

sequence listed when the equipment is to be
either locked-out or tagged-out for repair.
CA13082119

Locking out of service
1. Notify all employees who may be poten-

tially affected by the repair process on the
machine.
2. Secure the machine in a safe position. If

equipped, set the parking brake or hydrau- DANGER
lic lock lever in the PARK or LOCKED posi-
tion.
DO NOT OPERATE
When this is not being used,
3. Identify, remove or disconnect all power keep it in the storage compartment.
or energy sources and be sure to install a
Lockout/Tagout device on them. If the ma- CA13082120
chine is equipped with a Maintenance Alert
.
De al
Tag, attach this tag to the machine con-
pt
trols.
g n
4. Be sure all employees involved in the re-
pairs have installed there lock on the pow-
o
er source before performing any repairs.
Once an employee has completed there
in ti
repair procedure, they must remove there

lock and not access the machine in any
manor.
et a
n
Returning to service
rk er
1. The authorized person who performed the

Lock out/Tagout procedure shall check the
area around the machine to ensure that no
Ma t
one is exposed to any hazard before start-

In
up.
2. The authorized person who performed

the Lock out/Tagout shall ensure that
all guards have been reinstalled to their
proper place, all tools and equipment have
been removed and all locks are removed.
3. The authorized person who performed the

Lock out/Tagout shall verify that all controls
are in the neutral or “off” position and all
personnel are aware of the time the ma-
chine will be back in service.

4. Remove the Lockout/Tagout equipment

and any additional alert equipment and re-
energize the machine for return to service.
2.2.30 Chemical hazard
Exposure to hazardous chemicals pose a

serious danger if released or mishandled.
Handling hazardous materials often releases
substances that could pose a hazard. Tempo-
rary implication or possible residual injury may
result unless proper precautions are observed
while working with these materials. All work-
.
De al
ers involved in handling hazardous materi-
pt
als should use approved personal protective
equipment and follow all environmental safety
g n
regulations.
o
in ti
2.2.31 Material Safety Data Sheets
(MSDS)
Material Safety Data Sheet (MSDS) informa-

et a
tion relating to the materials the workers could

n
be exposed to.
rk er
● MSDS data sheets provide both workers

and emergency personnel with the proper
procedures for handling or working with a
Ma t
particular substance. Information includes

physical data, health effects, first aid, re-
In
activity, storage, disposal and protective

equipment required.
● Be sure all personnel involved are familiar

with all MSDS-related information as it re-
lates to the hazardous materials they could
be exposed to. Keep MSDS data sheets CA13082121
handy in site of all employees and emer-

gency personnel where they can be easily
accessed.
● Never handle hazardous materials with-

out the proper MSDS information. Always
verify the data on the MSDS sheet before
handling any hazardous materials.

2.3 Precautions for sling work

and giving signals
1. Only one appointed worker is allowed to
give signals and co-workers must commu-
nicate with each other frequently. The ap-
pointed signal person must give specified
signals clearly at a place where he is seen
well from the operator's seat and where he
can see the working condition easily. The
signal person must always stand in front of
the load and guide the operator safely.
● Do not stand under the load.
.
De al
● Do not step on the load.
pt
2. Check the slings before starting sling work.
g n
3. Always wear gloves during sling work.
o
(Wear leather gloves, if available.)
in ti
4. Measure the weight of the load by the eye

and check its center of gravity.
et a
5. Use proper sling according to the weight of

the load and method of slinging. If too thick
n
wire ropes are used to sling a light load,

rk er
the load may slip and fall.
6. Do not sling a load with 1 wire rope alone.

If it is slung so, it may rotate and may slip
Ma t
out of the rope. Install 2 or more wire ropes

In
symmetrically.
7. Limit the hanging angle to 60°, as a rule.

Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.

When hoisting a load with 2 or more ropes,

the force subjected to each rope will in-
crease with the hanging angle. The table
Load capacity kN(kg)

kN
below shows the variation of allowable kg
19.6
load in kN {kg} when hoisting is made with 2000 18.6
16.7
1900 13.7
2 ropes, each of which is allowed to sling 19.6 1700
1400
2000 9.8
up to 9.8 kN {1,000 kg} vertically, at various 1000
4.9
hanging angles. When the 2 ropes sling a 9.8
500
1000
load vertically, up to 19.6 kN {2,000 kg} of
total weight can be suspended. This weight
30 60 90 120 150
is reduced to 9.8 kN {1,000 kg} when the 2 Hanging angle (Deg.)
ropes make a hanging angle of 120°. If the ZX215-1000001
2 ropes sling a 19.6 kN {2,000 kg} load at
.
a lifting angle of 150°, each of them is sub-
De al
jected to a force as large as 39.2 kN {4,000
pt
kg}.
g n
8. When installing wire ropes to an angular
load, apply softeners to protect the wire
o
ropes. If the load is slippery, apply proper
in ti
material to prevent the wire rope from slip-

ping.
9. Use the specified eyebolts and fix wire

et a
ropes, chains, etc. to them with shackles,

n
etc.
rk er
10. Apply wire ropes to the middle portion of

the hook.
● Slinging near the tip of the hook may

Ma t
cause the rope to slip off the hook dur-

In
ing hoisting. The hook has the maxi-

mum strength at the middle portion.
11. Do not use twisted or kinked wire ropes.
12. When lifting up a load, observe the follow- 100% 88% 79% 71% 41%
ing.
ZX215-1000002

● Wind in the crane slowly until wire

ropes are stretched. When settling the
wire ropes with the hand, do not grasp
them but press them from above. If
you grasp them, your fingers may be
caught.
● After the wire ropes are stretched, stop

the crane and check the condition of
the slung load, wire ropes, and soft-
ener.
● If the load is unstable or the wire rope

or chains are twisted, lower the load
.
and lift it up again.
De al
pt
● Do not lift up the load slantingly.
g n
13. When lowering a load, observe the follow-
ing.
o
● When lowering a load, stop it temporar-
in ti
ily at 30 cm above the floor, and then

lower it slowly.
et a
● Check that the load is stable, and then

remove the sling.
n
● Remove kinks and dirt from the wire

rk er
ropes and chains used for the sling

work, and put them in the specified
place.
Ma t
In

Selecting wire ropes
Select adequate ropes as per the weight of parts to be hoisted, referring to the table below.
Wire ropes
(Standard “Z” twist ropes without galvanizing)
Nominal Diameter of Rope Allowable Load
mm kN Ton
10 9.8 1.0
11.5 13.7 1.4
12.5 15.7 1.6
.
14 21.6 2.2
De al
pt
16 27.5 2.8
18 35.5 3.6
g n
20 43.1 4.4
o
22.4 54.9 5.6
in ti
30 98.1 10.0
40 176.5 18.0
et a
50 274.6 28.0
60 392.2 40.0
n
rk er
CAUTION
● The allowable load is one-sixth of the
Ma t
breaking strength of the rope used

In
(Safety coefficient: 6).

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SY195/205/215/225C9 Crawler Hydraulic Excavator Specifications
Specifications
.
3 Specifications
De al
pt
3.1 Dimensions .............................................................................................................. 3-3
3.2 Working Ranges ...................................................................................................... 3-4
g n
3.3 Technical Specifications........................................................................................... 3-5
o
3.4 Weight Table ............................................................................................................ 3-8
in ti
3.5 Recommended Oil, Fuel and Coolant...................................................................... 3-9

3.6 Capacity Table ....................................................................................................... 3-10
3.7 Engine Performance Curve ....................................................................................3-11
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Specifications SY195/205/215/225C9 Crawler Hydraulic Excavator
.
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In
WARNING
jury or death.

3 SPECIFICATIONS
3.1 Dimensions
D I
E C
.
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pt
L
H
G F
g n J
K
B
o
in ti
CJ13032601-1
Unit: mm (ft, in)

et a
Item SY195C-9 SY205C-9 SY215C-9 SY225C-9

n
A Overall length (shipping) 9560 {31'4''} 9680 {31'9''} 9680 {31'9''} 9680 {31'9''}
rk er
B Overall width 2800 {9'2''} 2800 {9'2''} 2980 {9'9''} 2980 {9'9''}
C Overall height (Shipping) 3250 {10'8''} 3440 {11'3''} 3440 {11'3''} 3440 {11'3''}
D Width (top) 2710 {8'11''} 2710 {8'11''} 2710 {8'11''} 2710 {8'11''}
Ma t
E Overall height (to cab roof) 2990 {9'10''} 2990 {9'10''} 2990 {9'10''} 2990 {9'10''}
In
F Std. track shoe width 600 {1'12''} 600 {1'12''} 600 {1'12''} 600 {1'12''}
G Track gauge 2200 {7'3''} 2200 {7'3''} 2380 {7'10''} 2380 {7'10''}
H Min. ground clearance 440 {1'5''} 440 {1'5''} 440 {1'5''} 440 {1'5''}
I Tail swing radius 2890 {9'6''} 2890 {9'6''} 2890 {9'6''} 2890 {9'6''}
J Length of track on ground 3260 {10'8''} 3355 {11'0''} 3445 {11'4''} 3640 {11'11''}
K Track length 4060 {13'4''} 4160 {13'8''} 4250 {13'11''} 4445 {14'7''}

3.2 Working Ranges
.
a
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g
b g no
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e
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c d
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In
CJ13032602-1
Unit: mm (ft, in)

Item SY195C-9 SY205C-9 SY215C-9 SY225C-9
a Max. cutting height 9410 {30'10''} 9570 {31'5''} 9570 {31'5''} 9570 {31'5''}
b Max. dumping height 6490 {21'4''} 6700 {21'12''} 6700 {21'12''} 6700 {21'12''}
c Max. digging depth 6410 {21'0''} 6600 {21'8''} 6600 {21'8''} 6600 {21'8''}
d Max. vertical digging depth 5790 {18'12''} 5800 {19'0''} 5800 {19'0''} 5800 {19'0''}
e Max. digging reach 9740 {31'11''} 9950 {32'8''} 9950 {32'8''} 9950 {32'8''}
f Min. swing radius 3755 {12'4''} 3595 {12'12''} 3595 {12'12''} 3595 {12'12''}
g Max. height at min. swing radius 7700 {25'3''} 7665 {25'2''} 7665 {25'2''} 7665 {25'2''}

3.3 Technical Specifications
Machine model SY195C-9 SY205C-9 SY215C-9 SY225C-9

Bucket capacity m³ 0.8 0.8 0.9 1.0
Operating weight kg 21000 21200 21800 22600
Max. bucket digging force kN 135 138 138 138
Performance
Max. arm digging force kN 109 103 103 103

Swing speed rpm 11 11 11 11
Travel speed (Hi/Lo) km/h 5.4/3.3 5.4/3.3 5.4/3.3 5.4/3.3
Gradeability Deg. 35 35 35 35
Ground pressure kPa 47 46 47 46
.
Model Sany D06S2 MITSUBISHI 6D34-TL
De al
pt
Type 6-cylinder, 4-cycle, water-cooled, in-line, direct injection
No. of cylinders-bore x stroke
g n mm 6-Φ104 ×115
Engine
Piston displacement L 5.86

Rated power KW/rpm 114 / 2050
o
Max. torque N·m/rpm 590 / 1400
in ti
Max. speed at no load rpm 2200±50

Min. speed at no load rpm 1000±10
Min. fuel consumption g/KWh 210
et a
Starting motor 24V/5.0 KW

Alternator 24V/50A
n
Undercarriage
Carrier roller (each side) 2 2 2 2

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Track roller (each side) 7 7 8 9

Ma t
Track shoe (each side) 45 46 47 49

In
Type KAWASAKI (Variable displacement piston type)

valve lic pump
Hydraulic Control Hydrau-
L/min
Max. delivery 2×210
Mpa
Safety valve pressure 34.3
Type x No. KMX15RB/B45201B ×1
Control method Hydraulic
2 x KYB variable displacement piston type
Hydraulic system
Travel motor
(with brake valve and parking brake)
motor
1 x KAWASAKI angle type, piston type

Swing motor
(swing brake controller)
Type Double acting piston
Hydraulic
cylinder
Bore 120 (Boom), 135 (Arm), 115 (Bucket)

Rod diameter 85 (Boom), 95 (Arm), 80 (Bucket)
Stroke 1285 (Boom), 1490 (Arm), 1120 (Bucket)
Hydraulic tank Closed type
Hydraulic oil filter element Tank return side
Hydraulic oil cooler Air-cooling type

Engine
Item Specification
SY195/205C9: Sany D06S2

Engine model
SY215/225C9: Mitsubishi 6D34-TL
Type In-line 6-cylinder; water-cooled, 4-cycle diesel engine
Combustion chamber type Direct injection
Valve mechanism OHV
Max. output power kW{PS}/rpm 114{155}/2050
Max. torque N·m{kgf·m}/rpm 590{60}/1400
.
Bore×Stroke mm φ104×115
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pt
Total displacement cm³{L} 5860{5.860}
Compression ratio 18.2
g no
in ti
Swing motor
Producer KAWASAKI
et a
Model M5×180CHB-12A-51A/260
n
angle type, piston type

Type
(swing brake controller)
rk er
Theoretical displacement cm³/rev 129.2

Safety valve set pressure MPa {Kg/cm³} 25.5 {260}
Ma t
Rated engine speed rpm 2050

Brake release pressure MPa {Kg/cm³} 3.4 {34}
In
Control valve
Item Specification
Model KMX15RB
Standard flow rate (equivalent to one pump) 300 L/min
When main relief valve is normal 34.3 MPa
Maximum pressure
When main relief valve is boosting 37.3 MPa
Maximum pressure When port relief valve is normal 39.2 MPa
Working oil temperature -20~90°C
Drained oil maximum pressure 0.3 MPa

Travel motor
Maker KYB
Model MAG-170VP-3400E
Variable displacement piston type
Type
(w/ brake valve and parking brake)
Weight kg 275
Equivalent displacement cm³/rev qxi
Large displacement q1 cm³/rev 130.4
Motor displacement q
Small displacement q2 cm³/rev 74.9
Speed reduction rate i 60
2-speed switching Lo-Hi Mpa > 6.86
.
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Pilot pressure Hi-Lo Mpa > 1.96
pt
Braking torque g n N·m 398
Operating displacement L/min 228
Operating pressure Mpa 33.34
o
Peak pressure Mpa within 44.1
in ti
Acting times (above 34.3Mpa and below 44.1Mpa) times < 1,200,000
Large flow rpm 1679
Motor shaft
et a
Small flow rpm 2861

Swing speed
Large flow rpm 28
n
Reducer
Small flow rpm 47.7
rk er
Output torque KN·m within 37

Normal PS
Input power
Ma t
Maximum PS within 210 (within 30 consecutive sec.)

Normal Mpa within 0.2
In
Drain pressure
Momentary maximum Mpa within 0.5 (below 0.3 MHz)

3.4 Weight Table

Unit: kg
Machine Model SY195C-9 SY205C-9 SY215C-9 SY225C-9

Engine 520 520 520 520
Radiator assembly 80 80 80 80
Hydraulic tank assembly (w/o hydraulic oil) 148 148 148 148
Fuel tank assembly (w/o fuel) 126 126 126 126
Revolving frame 1770 1770 1770 1770
Operator cab 360 360 360 360
Operator seat & control console 75 75 75 75
.
De al
Counterweight 3900 3900 3900 3900
pt
Hydraulic pump 120 120 120 120
Control valve 185 185 185 185
g n
Swing reducer assembly
o
200 200 200 200
Final drive assembly 300×2 300×2 300×2 300×2
in ti
Center swivel joint 56 56 56 56
Track frame 2280 2432 2746 2746

Swing bearing 286 286 286 286
et a
Idler 116×2 116×2 116×2 116×2

n
Tensioning device 135×2 135×2 135×2 135×2

Carrier roller 25.5×4 25.5×4 25.5×4 25.5×4
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Track roller 40×14 40×14 40×16 40×18
Boom assembly 1568 1568 1590 1590

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Arm assembly 706 709 709 709

In
Bucket assembly 769 769 781 781

Boom cylinder assembly 206×2 206×2 206×2 206×2
Arm cylinder assembly 262 262 262 262
Bucket cylinder assembly 188 188 188 188
Linkage 68 68 68 68
Rocker 22×2 22×2 22×2 22×2

3.5 Recommended Oil, Fuel and Coolant
Ambient temperature
Fluid
Reservoir -22 -4 14 32 50 68 86 104 122°F
type
-30 -20 -10 0 10 20 30 40 50°C
SAE 30
SAE 10W
Engine oil pan
SAE 10W-30
SAE 15W-40
.
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Swing machinery
case Engine oil
g n
Idler
SAE 30
Track roller
o
Carrier roller
in ti
SAE 10W
et a
SAE 10W-30
n
SAE 15W-40
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Hydraulic system
L-HV32 Low-temp, wear-resistant
Ma t
hydraulic oil
Hydraulic
In
oil L-HM46 Wear-resistant hydraulic oil
L-HM68 Wear-resistant hydra. oil
ASTM D 975 No.2
Diesel
Fuel tank GB252 Super-20 Diesel fuel
fuel
GB252 Super-35 Diesel fuel
Grease fitting Grease NLGI No.2
Cooling system Coolant TEEC L35

● Machine oil above API CF-4 (no lower than APC CD) is recommended.
● Gear oil GL-5 is recommended.
● Obtain genuine oil from Sany Heavy Machine or its authorized dealers.
3.6 Capacity Table

Unit: L {US Gal}
Swing mecha- Final drive Hydraulic
Engine oil pan Cooling system Fuel tank
nism casing casing system
22 {5.81} 4.0 {1.06} 5.5 {1.45} 239 {63.14} 22.5 {5.94} 340 {89.82}
.
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3.7 Engine Performance Curve

Testing condition:
1) Temperature: 298K, one standard atmospheric pressure. 2) No fan.
N·m
Torque
600
Torque
500
400
.
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pt
300
kW
g no
120
in ti
Power output
100
et a
Power output
80
n
rk er
60
Ma t
In
40
g/kw·h
Fuel consumption
20 240
Fuel consumption
230
220
210
1000 1200 1400 1600 1800 2000

-1
Engine speed min
ZX215-1001003

Et.
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SY195/205/215/225C9 Crawler Hydraulic Excavator Structure and Function
Structure and Function
.
4 Structure and Function
De al
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4.1 Engine and Cooling System .................................................................................... 4-5
4.1.1 Engine-related parts....................................................................................... 4-5
g n
4.1.2 Radiator and intercooler................................................................................. 4-6
o
4.2 Power Train.............................................................................................................. 4-7
in ti
4.2.1 Power transmission system .......................................................................... 4-7

4.2.2 Final drive assembly ...................................................................................... 4-8
4.2.3 Swing machinery.......................................................................................... 4-12
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4.2.4 Swing bearing .............................................................................................. 4-14

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4.3 Undercarriage and Frame...................................................................................... 4-15

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4.3.1 Track frame and recoil spring....................................................................... 4-15

4.3.2 Idler .............................................................................................................. 4-17
4.3.3 Carrier roller ................................................................................................. 4-19
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4.3.4 Track roller ................................................................................................... 4-20

In
4.3.5 Track shoe ................................................................................................... 4-21

4.3.6 Triple grouser shoe ...................................................................................... 4-25
4.4.1 Hydraulic equipment layout.......................................................................... 4-26
4.4.2 Hydraulic tank and filter ............................................................................... 4-28
4.4.3 Hydraulic pump ................................................................................................... 4-29
4.4.4 Pilot pump .................................................................................................... 4-36
4.4.5 Regulator .................................................................................................... 4-37
4.4.5.1 Control mechanism makeup ............................................................... 4-39
4.4.5.2 Adjustment of the regulator ................................................................. 4-40
4.4.5.3 Operation ............................................................................................ 4-42
4.5.1 Control valve ................................................................................................ 4-45

Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator
4.5.2 Operating principle ....................................................................................... 4-48

4.5.2.1 When spool is in neutral position ........................................................ 4-48
4.5.2.2 Travel .................................................................................................. 4-50
4.5.2.3 Arm...................................................................................................... 4-51
4.5.2.4 Boom................................................................................................... 4-56
4.5.2.5 Bucket ................................................................................................. 4-59
4.5.2.6 Swing .................................................................................................. 4-61
4.5.2.7 Option ................................................................................................. 4-63
4.5.2.8 Travel straight ..................................................................................... 4-64
4.5.2.9 Lock valve function ............................................................................. 4-65
4.5.2.10 Main relief valve function .................................................................. 4-67
.
4.5.2.11 Port relief valve function .................................................................... 4-68
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4.5.3 Section view ................................................................................................. 4-72
g n
4.6.1 Swing motor ................................................................................................. 4-83
o
4.6.2 Swing holding brake..................................................................................... 4-85
4.6.3 Relief valve portion ...................................................................................... 4-86
in ti
4.6.4 Reverse prevention valve ............................................................................ 4-88

4.6.4.1 Operation drawing............................................................................... 4-88
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4.6.4.2 Explanatory drawing of effects ............................................................ 4-89

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4.6.5 Center swivel joint ........................................................................................ 4-91

4.6.6 Travel motor ................................................................................................. 4-93
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4.6.6.1 Operation of components.................................................................... 4-95

4.6.7 Valve control system .................................................................................. 4-107
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4.6.8 Pilot valve.................................................................................................. 4-109

In
4.6.8.1 Work equipment and swing pilot valve.............................................. 4-109

4.6.8.2 Travel PPC valve ...............................................................................4-113
4.6.9 Solenoid valve.............................................................................................4-117
4.6.10 Accumulator ..............................................................................................4-118
4.6.11 Pilot oil filter ...............................................................................................4-119
4.6.12 Pump oil pressure sensor ........................................................................ 4-120
4.6.13 Hydraulic cylinder..................................................................................... 4-121
4.6.14 Work equipment ....................................................................................... 4-123
4.7 Air Conditioning System....................................................................................... 4-129
4.7.1 A/C components layout drawing ................................................................ 4-130
4.7.2 Control panel.............................................................................................. 4-131
4.7.3 Circuit diagram ........................................................................................... 4-132
4.7.4 Refrigeration principle ................................................................................ 4-134

4.7.4.1 Refrigeration cycle diagram .............................................................. 4-134

4.7.4.2 Heating cycle diagram ...................................................................... 4-134
4.7.5 Compressor ............................................................................................... 4-135
4.7.6 Clutch ......................................................................................................... 4-137
4.7.8 Condenser ................................................................................................. 4-138
4.7.7 Expansion valve ......................................................................................... 4-138
4.7.9 Evaporator ................................................................................................. 4-139
4.7.10 Receiver tank ........................................................................................... 4-139
4.7.11 Pressure switch ........................................................................................ 4-140
4.7.12 Fresh air sensor ....................................................................................... 4-141
4.7.13 Refrigerant ............................................................................................... 4-141
.
4.7.14 Compressor oil ......................................................................................... 4-160
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pt
4.8 Engine Control ..................................................................................................... 4-161
4.8.1 System operation ...................................................................................... 4-162
g n
4.8.2 Components............................................................................................... 4-163
o
4.8.2.1 Fuel control dial................................................................................. 4-163
4.8.2.2 Controller .......................................................................................... 4-165
in ti
4.9 Electrical Control System..................................................................................... 4-167

4.9.1 Control function .......................................................................................... 4-167
et a
4.9.2 Machine control system diagram ............................................................... 4-168

n
4.9.3 Engine and pump composite control function ............................................ 4-170

4.9.4 Pump control function ................................................................................ 4-174
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4.9.4.1 Electrical positive flow control ........................................................... 4-175

4.9.4.2 Constant power control ..................................................................... 4-178
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4.9.5 Valve control function ................................................................................. 4-180

In
4.9.5.1 Bucket flow control ............................................................................ 4-181

4.9.5.2 Swing priority control......................................................................... 4-182
4.9.6 Duo travel speed control ............................................................................ 4-183
4.9.7 Engine preheating/overheating alarm ....................................................... 4-185
4.9.7.1 Engine preheating ............................................................................. 4-186
4.9.7.2 Engine overheating alarm ................................................................. 4-187
4.9.8 Engine oil under–pressure alarm ............................................................... 4-187
4.9.9 Auto deceleration/acceleration control ....................................................... 4-188
4.9.10 Engine speed calibration function ............................................................ 4-190
4.9.11 Electrical Components ............................................................................. 4-192
4.9.11.1 Pump pressure sensor .................................................................... 4-192
4.9.11.2 Pilot pressure sensor ...................................................................... 4-193
4.9.11.3 Engine speed sensor ...................................................................... 4-194

4.9.11.4 Coolant temperature sensor............................................................ 4-195

4.9.11.5 Fuel level sensor ............................................................................. 4-196
4.9.11.6 Oil pressure switch .......................................................................... 4-197
4.10 Monitoring System ............................................................................................. 4-198
4.10.1 Machine monitor ...................................................................................... 4-199
4.10.2 Monitor functions...................................................................................... 4-200
4.10.3 Monitor operation ..................................................................................... 4-203
.
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In
WARNING
jury or death.

4 STRUCTURE AND FUNCTION
4.1 Engine and Cooling System
4.1.1 Engine-related parts
.
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In
1 2 3 4 5 6 7
ZX215-1002001
(1) Fan Specification

(2) Front engine mount
Oil capacity: 22 L
(3) Fuel filter
(4) Start motor
(5) Rubber damper assembly
(6) Rear engine mount
(7) Muffler

4.1.2 Radiator and intercooler
3 2 1
.
De al
7
pt
g no
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8
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9
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WX215-1204009G
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(1) Radiator outlet hose

In
Specifications
(2) Radiator inlet hose
Radiator assembly:
(3) Radiator
ZH860×385×1050-S70Y75Z20Q/SY015
(4) Intercooler air intake
(5) Reserve tank Aluminum pipe, belt-type radiator
(6) Intercooler Radiator and oil cooler in parallel connection;

(7) Intercooler air outlet intercooler in series connection with radiator
and oil cooler.
(8) Fan guard
(9) Radiator cap Reservoir capacity: 8.9 L (2.35 US gal)
Engine coolant capacity: 9.5L (2.51 US gal)

4.2 Power Train
4.2.1 Power transmission system
3 2 1
.
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pt
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4 5 6 7 8 9
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10
Ma t
In
ZX215-1002003
(1) Swing motor (6) Accumulator

(2) Swing reducer (7) Control valve
(3) Swing bearing (8) Final drive AS
(4) Idler (9) Hydraulic pump
(5) Central swivel joint (10) Engine

4.2.2 Final drive assembly
Final drive AS (KYB)
1 2 3 19 4 17
73±3.6 N·m
205±10 N·m
5
59±4.9 N·m
20
.
De al
6
pt
7
g no
in ti
18
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8
n
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157±8 N·m
12
Ma t
11 16 10 9
In
ZX215-1002004-1
13
14
15
ZX215-1002005

(1) Cylinder GP (9) No. 2 sun gear (No. of teeth: 19)

(2) Shaft (10) No. 2 planetary gear (No. of teeth: 36)
(3) Gear hub (No. of teeth: 85) (11) Seal ring
(4) No. 2 planetary carrier (12) Travel motor
(5) No. 1 planetary carrier (13) Fill port
(6) No. 1 planetary gear (No. of teeth: 36) (14) Level port
(7) No. 1 sun gear (No. of teeth: 12) (15) Drain port
(8) End cover
Specifications
Reduction ratio:
.
De al
( (12+85) /12) × ( (19+85) /19) ) -1= 43.246
pt
g n Criteria
No. Check item Remedy
o
Standard clearance Clearance limit
Backlash between No. 2 sun gear
in ti
16 0.13 – 0.47 1.00 Replace

and No.2 planetary gear
Backlash between No. 1 planetary
17 0.17 – 0.57 1.10
et a
gear and gear hub

n

18 0.14 – 0.46 1.00
rk er
Replace
19 0.16 – 0.56 1.10
gear and gear hub
Ma t

20 0.38 – 0.66 1.00
carrier and No. 2 sun gear
In

Final drive AS (Daewoo)
22
6
22
3 14 15
25 24
3
.
26
De al
4 10 29 21
33 2
pt
9
23
g n 13 27
12
28
11 1
o
8
32 20
in ti
9
30 19
31
17 7
et a
5 18 27 16
WX215-1204010G
n
rk er
(1) O-ring (13) Planetary gear shaft (25) Seal ring

(2) Mandrel (14) Sun gear (26) O-ring
(3) Float seal (15) Snap ring (27) Thrust washer
Ma t
(4) Gear carrier (16) Planetary gear (28) Thrust washer

In
(5) Hub (17) Needle bearing (29) Thrust plate

(6) Spacer (18) Drive gear (30) Gear carrier
(7) Planetary gear shaft (19) Spring pin (31) Gasket
(8) Planetary gear (20) End cover (32) O-ring
(9) Thrust washer (21) Socket head bolt (33) O-ring
(10) Spring pin (22) Radial thrust ball bearing (34) Fill port
(11) Needle bearing (23) O-ring (35) Level port
(12) Floating bush (24) Plug (36) Drain port

4.2.3 Swing machinery
20
19
8
21
7
.
De al
22
pt
59~74 N·m
10
g n
6
o
23
5 24
in ti
11
4
12
et a
25
n
26
rk er
13
3
27
Ma t
2
In
1 14
15
16
17
18
28
ZX215-1002007

(1) Plug (11) No. 2 planetary gear GP

(2) Oil seal (12) No. 2 planetary gear (No. of teeth:17)
(3) Self-aligning bearing (13) Spring pin
(4) Ring gear (No. of teeth:52) (14) Swing reducer screw plug
(5) No. 2 planetary carrier (15) Grease fitting
(6) No. 1 planetary carrier (16) Self-aligning bearing
(7) No. 2 sun gear (No. of teeth: 16) (17) Bearing sealing
(8) No. 1 sun gear (No. of teeth:14) (18) Swing pinion
(9) Swing motor (19) Dipstick
(10) No. 1 planetary gear (No. of teeth:18) (20) Oil filling pipe
.
Specifications
De al
Reduction ratio:
pt
(14+25) /14× (16+25) /14= 20.04
g no
Unit: mm
in ti
Criteria
No. Check item Remedy
Backlash between swing motor shaft
et a
21 0.18 – 0.28 — Replace

and No. 1 sun gear
n

22 0.16 – 0.50 1.00
rk er

23 0.18 – 0.59 1.10
gear and ring gear
Ma t

24 0.39 – 0.71 1.20
In
carrier and No. 2 sun gear

25 0.16 – 0.50 0.90 Replace
26 0.18 – 0.59 1.00
gear and ring gear
27 0.07 – 0.23 —
carrier and swing pinion
Backlash between swing pinion and
28 0.22 – 1.32 2.00
swing bearing

4.2.4 Swing bearing
A
A
.
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1
g no
2
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3
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Ma t
In
549±50 N·m
549±50 N·m
A-A
ZX215-1002008
(1) Swing bearing inner race (Teeth: 91) Specifications

(2) Ball
Reduction ratio: 91/13= 7
(3) Swing bearing outer race
Amount of filled grease: 13±1 Kg
a. Inner race soft zone S position
b. Outer race soft zone S position Unit: mm
Check item Criteria Remedy
Axial clearance of bearing Standard clearance Clearance limit

Replace
(when mounted on chassis) 0.5~1.6 3.2

4.3 Undercarriage and Frame
4.3.1 Track frame and recoil spring
1 2 3 4
.
De al
pt
g n
8 7 6 5
o
10
in ti
et a
9
n
11
rk er
X
Ma t
X
In
ZX215-1002009
(1) Idler ● Dimension and number of track rollers may

(2) Track frame vary depending on the machine model, but
the basic structure is the same.
(3) Carrier roller
(4) Sprocket
Model Q'ty (One side)
(5) Track roller
SY195C9 7
(6) Track shoe
SY205C9 7
(7) Center guard
SY215C9 8
(8) Front guard
SY225C9 9

Standard track shoe
Model
SY195C9 SY205C9 SY215C9 SY225C9
Item
Shoe width(mm) 600 600 600 600
Link pitch(mm) 190 190 190 190
Q'ty (One side) 45 46 47 49
Unit: mm
No. Check item Criteria Remedy

Standard size Tolerance Repair limit
.
De al
Vertical width of
9 Track frame 107 — — Build-up
pt
idler guide
Idler support 105 — — welding or
Track frame 250 — — replace
10
g n
Horizontal width
of idler guide Idler support 247 — —
o
Standard size Repair limit
in ti
Free length
Installation Installation Free Installation
x Outside
11 Recoil spring length load length load Replace
diameter
et a
157.9 kN
598 x 247 466 545 133.9 kN
n
{16112 kg}
rk er
Ma t
In

4.3.2 Idler
4
3
.
157~255 Nm
De al
pt
g no
in ti
1 2
et a
n
rk er
Ma t
In
W13081901

Unit: mm
Outside diameter of protru- Standard size Repair limit

1
sion 560 —
2 Outside diameter of tread 520 508 Build-up
3 Thickness of tread 30 24 welding or
4 Difference of tread 20 26 replace
5 Total width 164 —
6 Width of tread 39.5 —
7 Diameter of shaft 65 —
.
Clearance between bush-
De al
Replace
8 ing and support (Sum of
pt
0.5~1.0 —
clearance at both sides)
g no
in ti
et a
n
rk er
Ma t
In

4.3.3 Carrier roller
5 3
.
De al
pt
4
g n
2 1
6 7
o
in ti
et a
ZX215-1002011
n
rk er
Unit: mm

Ma t

1 Outside diameter of flange
165 —
In
2 Outside diameter of tread 140 130

3 Width of tread 44 —
4 Thickness of tread 41.5 34
5 Width of flange 18 —
Standard Tolerance Standard Clearance
Clearance between shaft Replace
6 size Shaft Hole clearance limit
and bushing
50 — — — —
Standard Tolerance Standard Interfer-
Interference between roller
7 size Shaft Hole interference ence limit
and bushing
57 — — — —
8 Axial clearance of roller
0.44 – 0.76 —

4.3.4 Track roller
8 2 1
.
De al
549±59 Nm
pt
g no
7 5 6
in ti
4
W13081902
et a
Unit: mm
n
rk er

Standard clearance Repair limit
1 Outside diameter of flange
193 —
Ma t
2 Outside diameter of tread 160 148

In
Build-up weld-
3 Thickness of tread 46.5 40.5
ing or replace
4 Total width 237 —
5 Width of tread 46.5 —
6 Width of flange 32 —
7 Inside width 80
8 Diameter of shaft 65 —
Clearance between bushing Standard clearance Clearance limit Replace
9
and collar 0.5 – 1.0 —

4.3.5 Track shoe
.
De al
pt
g no
19
in ti
21 23
7
15 11
et a
12
n
10 20
rk er
22 24
6 5 14 2 8 3 13
Ma t
In
17 16 18 W13100801

Unit: mm

1 Link pitch
190 193
Reverse or replace
2 Outside diameter of bushing
59.45 53.7
3 Thickness of bushing metal 10.75 5.75
Standard size Repair limit Repair or replace
4 Link height
105 98
5 155.57
6 Shoe bolt pitch 119.57
.
De al
7 69
pt
8 g n Inside width 82.57
9 Link Overall width 40
10 Tread width 38
o
Regular 2.7
in ti
11 Protrusion of pin
Master 2.7 Adjust or replace
Regular 3.7
12 Protrusion of bushing
et a
Master 0.0
Regular 207
n
13 Overall length of pin

Master 209
rk er
Regular 136
14 Overall length of bushing
Master 128.5
Ma t
15 Thickness of spacer —
16 Bushing 88.2 – 245 kN {9 – 25 ton}
In
17 Press-fitting force Regular pin 127.4 – 274.4 kN {13 – 28 ton} —

18 Master pin 78.4 – 147 kN {8 – 15 ton}

Unit: mm
Tightening torque (Nm {kgm}) Retightening angle (°)

a. Regular link Triple grouser 750±22.5
120±10
19 Shoe bolt shoe {62.5±2.3} Retighten
Tightening torque Retightening angle Lower limit torque
b. Master link (Nm {kgm}) (°) (Nm {kgm})
— — —
Tolerance Standard interfer-
Standard size
Interference between Shaft Hole ence
20
bushing and link 0 -0.25
59.45 0.20 – 0.32
.
-0.05 -0.32
De al
Interference between regu- 0 –0.23
pt
21 38.25 0.19 – 0.29
lar pin and link -0.04 –0.29
Tolerance
g n Standard size
Standard clear-
Clearance between regular Shaft Hole ance
o
22
pin and bushing 0 0.8 Adjust or
38.25 0.50 – 0.84
in ti
-0.04 0.5 replace

Tolerance Standard interfer-
Standard size
Interference between mas- Shaft Hole ence
23
et a
ter pin and link -0.08 -0.23

38.25 0.12 – 0.21
n
-0.11 -0.29
Tolerance Standard clear-
rk er
Standard size
Clearance between master Shaft Hole ance
24
pin and bushing -0.5 1
38.25 1 – 1.7
Ma t
-0.7 0.5
In

4.3.6 Triple grouser shoe
5 6 7
1
8
.
2
De al
3 4
pt
g no
ZX215-1002014
Unit: mm
in ti

1 Height
et a
26 16
n
2 Thickness 10
3 29.5
rk er
Length of base
4 22 Build-up welding
5 20.5 or replace
Ma t
6 Length at tip 17
In
7 18
8 Thickness
36 26

4.4 Hydraulic System, Part 1
4.4.1 Hydraulic equipment layout
(1) Bucket cylinder

(2) Arm cylinder
(3) Boom cylinder
(4) Hydraulic tank
(5) Hydraulic oil filter
(6) Control valve
.
(7) Hydraulic pump
De al
(8) Radiator
pt
(9) Accumulator g n
(10) Left travel motor
(11) Right travel motor
o
1
(12) Swing motor
in ti
(13) Lockout lever

(14) Left pilot valve
et a
(15) Center swivel joint

(16) Right pilot valve
n
(17) Travel pilot valve

rk er
(18) Solenoid valve assembly

18A. Pilot lockout solenoid valve
Ma t
18B. Boom priority solenoid valve

In
18C. Bucket confluence solenoid valve

18D. Swing priority solenoid valve
18E. Hi/Lo travel speed solenoid valve

3 4 5 6 7 8
.
De al
pt
g no
in ti
et a
n
rk er
A
Ma t
In
10
11
A
12
18A
13 18B
14 18C
18D
15 18E
16
17
18
W13081903

4.4.2 Hydraulic tank and filter
.
De al
pt
g no
3 4 5 6
in ti
et a
n
A
A
rk er
Ma t
In
7
A-A
ZX215-1002017
(1) Hydraulic tank Specifications

(2) Level gauge Tank capacity: 239 L (63 US gal)
(3) Oil filler cap Available capacity: 172 L (45.5 US gal)
(4) Return oil filter element
Breather valve
(5) Bypass valve
Filter fineness: 10μm
(6) Breather valve
Ambient temperature: -20~100°C
(7) Oil-suction filter element
Set pressure:
Air inlet side: 0.005MPa
Air outlet side: 0.05MPa

4.4.3 Hydraulic pump
Type: K3V112DTP1N9R
a1 PH1 PH2 a2
{36N.m} {36N.m}
a5
A1 A2 {16N.m}
a4
.
{36N.m}
De al
pt
g no
in ti
乎ᯊ䩜ᮟ䕀
B3
et a
DR1{170N.m}
B1 DR2{170N.m}
n
a3
5 Psv2 {36N.m}
rk er
4
Ma t
In
A3
DR3{170N.m} DR4{170N.m}
3 2 1
ZX215-1002018

Outline
● This pump consists of 2 variable capacity swash plate plunger pumps, 2 regulators, and 1 pi-
lot gear pump.
NOTE: For the location of the hydraulic pump on the machine, see “Hydraulic equipment layout”
on page 4-24.
a1: F. pump main pressure detection port (1) Front pump

a2: R. pump main pressure detection port (2) Rear pump
a3: F. pump regulator pressure detection port (3) Pilot gear pump
a4: Adjustor control pressure detection port (4) Front pump regulator
a5: Pilot gear pump output pressure detection port (5) Rear pump regulator
.
De al
PH1: F. pump pressure sensor assembly port
pt
PH2: R. pump pressure sensor assembly port
A1: F. pump delivery port
g n
A2: R. pump delivery port
o
A3: Pilot gear pump delivery port
in ti
Psv1: F. pump regulator control port

Psv2: R. pump regulator control port
Dr1: F. pump drain plug
et a
Dr2: R. pump drain plug

n
Dr3: Air bleeder

rk er
Dr4: Drain plug

B1: Pump suction port
B3: Pilot gear pump oil suction port
Ma t
In

2 3 13 6 7 14 8 9 16 10
15
.
1
De al
pt
12
4
g no
5 11
ZX215-1002019
in ti
(1) Front shaft (9) End cover

(2) Min. delivery adjusting screw (10) Rear shaft
et a
(3) Front casing (11) Rear casing

n
(4) Swash plate (12) Gear pump

rk er
(5) Slipper (13) Piston

(6) Plunger (14) Max. delivery adjusting screw
(7) Cylinder block (15) Gear shaft
Ma t
(8) Valve plate (16) Driving pin

In

B 6 13 7 8
.
1
De al
pt
18
18 4
g n
A
o
5 17
ZX215-1002020
in ti
Function
et a
● The torque of the engine is transmitted

to the pump shaft (1), and drives cylinder
n
block (7) to rotate. At the same time, nine

rk er
plungers (6) slide along the thrust plate (8).

Plunger (6) moves back and forth inside
cylinder block (7) and pressurized oil is
sucked and discharged alternatively.
Ma t
In
● It is possible to change the discharge

amount by changing the swash plate an-
gle.

Structure
● Cylinder block (7) is supported to shaft (1)

by spline (17).
● Shaft (1) is supported by front and rear

bearings (18).
● Tip of plunger (6) is shaped as a concave

ball and slipper (5) is caulked to it to form
one unit.
● Plunger (6) and slipper (5) constitute the

spherical bearing.
.
● Swash plate (4) has flat surface (A), and
De al
slipper (5) is always pressed against this
pt
surface while sliding in a circular move-
ment.
g n
● Swash plate (4) conducts high pressure oil
o
to cylinder surface (B), and forms a static
in ti
pressure bearing when it slides.
● Plunger (6) carries out relative movement

in the axial direction inside each cylinder
et a
chamber of cylinder block (7).

n
● Cylinder block (7) seals the pressurized oil

rk er
to thrust plate (8) and carries out relative

rotation.
● This surface is designed so that the oil

Ma t
pressure balance is maintained at a suit-

In
able level.
● The oil inside the respective cylinder cham-

bers of cylinder block (7) is sucked in and
discharged through thrust plate (8).

Operation of pump
1 4 5 7
A
● Cylinder block (7) rotates together with
shaft (1), and slipper (5) slides on flat sur-
face (A).
● When this happens, swash plate (4) moves

along cylindrical surface (B), so angle (a) a
between central line (X) of swash plate (4) X
and the axial direction of cylinder block (7) B ZX215-1002021
changes.
● (a) is named the swash plate angle.
.
De al
● With central line (X) of swash plate (4) at 4 5 6
pt
A F
a swash plate angle (a) in relation to the
axial direction of cylinder block (7), flat sur-
g n
face (A) acts as a cam in relation to slipper
o
(5).
in ti
● In this way, plunger (6) slides on the in- a
side of cylinder block (7), so a difference X
between volumes (E) and (F) is created 7

E
et a
ZX215-1002022
inside cylinder block (7).
n
● A single plunger sucks and discharges the

oil by the amount (F) – (E).
rk er
● As cylinder block (7) rotates and the vol-

ume of chamber (E) becomes smaller, the
Ma t
pressurized oil is discharged.

In
● On the other hand, the volume of chamber

(F) grows larger and, in this process, the
oil is sucked.
● As central line (X) of swash plate (4) over- F
laps the axial direction of cylinder block (7)

(swash plate angle (a) = 0), the difference
between volumes (E) and (F) inside cylin-
der block (7)becomes 0.
● Suction and discharging of pressurized

oil is not carried out in this state. Namely E
pumping action is not performed. (In real- 4 7 ZX215-1002023
ity, however, the swash plate angle is not
set to 0)

Control of delivery
● If swash plate angle (a) becomes larger,

13 16 F
the difference between volumes (E) and
(F) becomes larger and pump delivery (Q)
increases.
● Piston (13) is used for changing swash

plate angle (a).
● Piston (13) carries out linear alternating

motion under the control of the adjustor.
a
● This linear motion is transmitted to swash

plate (4) via drive pin (16). The sliding of
.
De al
the swash plate changes the swash plate 4 E
ZX215-1002024
pt
angle and changes the discharge amount
of the main pump.
g no
in ti
et a
n
rk er
Ma t
In

4.4.4 Pilot pump
NOTE: For the location of the pilot pump on the machine, see “Hydraulic equipment layout” on
page 4-24.
435 433 710 700 354 351
434
310
.
355
De al
pt
732
g n
311
o
312
in ti
309 307 308 434 850 466 725 435 361 353
et a
ZX215-1002025
n
rk er
307: Valve stem 361: Body

308: Valve base 433: Screw
Ma t
309: Retainer 434: Screw

In
310: Spring 435: screw

311: Adjusting screw 466: Plug
312: Nut 700: Washer
351: Body 710: O-ring
353: Gear shaft 725: O-ring
354: Gear shaft 732: O-ring
355: Filter element 850: Washer
Function
● The engine actuates the main pump and

the drive shaft of the pilot pump through
the transmission case, and drives the pilot
pump through gear engagement.

4.4.5 Regulator
(KR3G-0E11-AV)
NOTE: Both the front pump and the rear pump are equipped with a regulator. For the location of
the hydraulic pump, see “Hydraulic equipment layout” on page 4-24.
SKY5P 079
- 17 - S
496 418
PSV B
KDRDE5C-1
.
624 627 646 897 415
A
De al
325
pt
408 a
496
g n 924
801 601
755
o
402 614
466
543
656
407 643 755
A 756
in ti
733
631 708 545
724
731 887 611
651 652 733 541
et a
n
A-A
(KDRDE5K) PSV Tightening torTue
Name plate and s/n
rk er
Tightening torTue
Part No. Thread size
a Nm Type
402, 407
408 M6 12
415 M8 29 s/n
Ma t
G-OE11-V
418 M5 6.9
466 G1/4 16
In
496 NPTF1/16 8.8

614 G1/4 36 Direction B
801 M10 29
Hydraulic schematic diagram
ZX225-1102002

Category Part No. Part name Q’ty Remark

C 924 Hexagon socket head locating screw 1
/ 897 Pin 1
/ 887 Pin 1
D 801 Hexagon nut 1 JIS B 1181 N-M10
D 756 O-ring 2
D 755 O-ring 2
D 733 O-ring 2
D 731 O-ring 1
D 724 O-ring 5
D 708 O-ring 1
.
De al
/ 656 Cover plate 1
pt
/ 652 Spool valve 1
/ 651 Sleeve 1
g n
/ 646 Guide spring 1
o
/ 643 Pilot plunger 1
in ti
/ 631 Pf pilot sleeve 1

/ 627 Adjusting roller 1
/ 624 Spring seat 1
et a
/ 614 Plug 1
n
/ 611 Feedback lever 1

rk er
/ 601 Casing 1
/ 545 Ball 2
/ 543 Stopper 2
Ma t
/ 541 Valve seat 2

In
C 496 Embedded plug 9

C 466 VIP plug 1
D 418 Hex socket head bolt 2 JIS B 1176 M5-12
/ 325 Valve body 1
B 079 Sol proportional reducing valve 1
B — Regulator assembly 1
B: Assembly obtainable at the dealers (individual parts not purchasable)

/: Individual components included in assemblies of category B
C: Parts obtainable at the dealers
D: Parts obtainable on the market

Function
● The regulator controls the pump discharge PSV

amount according to the command signal
pressure, keeping the driving power of the
pump lower than the engine output.
a
● Pumps 1 and 2 are both equipped with a
regulator. Key components of the regulator 1
include a solenoid proportional pressure
reducing valve (1), a positive flow regulator
(2), a servo reversing valve (3) and a servo
2
piston (4). The regulator opens and shuts
the oil circuit of the servo piston (3) and
.
De al
changes the tilting angle of the hydraulic
pt
tank according to various command signal 3
4
pressure so as to control the pump dis-
g n
charge amount. ZX225-1102003
o
in ti
4.4.5.1 Control mechanism makeup
Current control
et a
● The inclination (output delivery amount)

n
of the pump can be controlled freely by

rk er
changing of the command current I flow-

ing into the solenoid proportional pressure
reducing valve. This regulator applies posi-
Ma t
tive flow control (positive control), through

which output delivery amount Q changes
In
according to the increase of command cur-

rent. Necessary current for corresponding
operation can be input through this control
mechanism. The pump only delivers nec-
essary oil amount and wastes no useless
power.

4.4.5.2 Adjustment of the regulator
806 532 548 531 808 954
953
.
De al
pt
g no
ZX215-1002028
in ti
531: Inclination pin

et a
SKY5P
532: Servo piston

- 17 - S
n
548: Feedback pin PSV

rk er
KDRDE5C-1
806: Retaining nut

808: Retaining nut 924
Ma t
953: Adjusting screw

In
954: Adjusting screw
● It is possible to adjust the maximum and

minimum flow by the adjusting screws (953, ZX225-1102004
954) in the pump block side. Flow control
features can be adjusted with the hexagon
socket head locating screw (924) on the
regulator.

Maximum flow adjustment (pump block

side)
● Loosen the hexagon nut (808), and tighten

(or loosen) hexagon socket head locating
screw (954). No control features except the
maximum flow changes.
Output flow Q
.
De al
Command current I
ZX215-1002033
pt
g no
Minimum flow adjustment (pump block
in ti
side)
● Loosen the hexagon nut (806), and tighten

et a
(or loosen) the hexagon socket head locat-

ing screw (953). Though this action is the
n
same as the adjustment of maximum flow

Output flow Q
rk er
and all the other control features do not

change, power required under maximum
output pressure (overflow) is likely to in-
crease if over-tightened. Be careful in this
Ma t
case.
In
Command current I
ZX215-1002034

Flow control feature adjustment
● After hexagon nut (810) is loosened, tight-

en (or loosen) the hexagon socket head lo-
cating screw (924) to carry out adjustment.
When the hexagon socket head locating
Output flow Q
screw (924) is being tightened, the control
diagram (as shown) will move to the right.
Command current I
.
ZX215-1002037
De al
pt
g no
in ti
4.4.5.3 Operation
Flow control
et a
● The output flow of the pump can be con-

Output flow Q
n
trolled by the command current I, as

shown.
rk er
Ma t
In
Command current I
ZX215-1002030

Action of increasing flow rate
● When command current I increases, the 079

solenoid proportional pressure reducing
651 652
valve secondary pressure P2 will increase,
627 646
and the spool valve (652) will move the 643
P1 801
right with the help of the guide piston (643). 924
When a relative balance between the right- 611
ward hydraulic force and the spring force 808 A 532

806
of guide spring (646) is achieved, spool 954 953
valve (652) stops moving.

P1
● As spool valve (652) moves to the right,

because port cl and tank port are intercon- Tilt angle large
.
nected, pressure of the large diameter ZX225-1102005
De al
portion of the servo piston is released and
pt
servo piston (532) moves to the left via the
output pressure P1 in the shall diameter
g n PSV
portion. The inclination becomes larger.
o
● Since feedback lever (611) is integrated
in ti
with the servo piston and valve sleeve a

(651), if servo piston (632) moves to the
left, feedback lever swings with point A as
et a
the pivot. In this way, valve sleeve moves

to the right.
n
● Through this movement, the opening por-

rk er
tion between the spool and the valve block

is closed slowly. The servo piston stops
ZX225-1102006
moving when the opening portion is com-
Ma t
pletely closed.
In

Action of reducing flow rate
● When command current I decreases, the 079

solenoid proportional pressure reducing
651 652
valve secondary pressure P2 will decrease,
627 646
and guide piston (643) will move to the left. 643
801
P1
However, as spool valve (652) moves, out- 924
put pressure P1 is introduced into the large 611
532
diameter chamber of the servo piston via 808 A
806
954
the port cl. On the other hand, output pres- 953
sure P1 is introduced into the small diam-

P1
eter chamber of the servo piston and servo
piston moves to the right via are difference.
The inclination becomes smaller. Tilt angle small
.
ZX225-1102007
De al
● As servo piston (532) moves to the right,
pt
the feedback lever swings with point A as
PSV
the pivot and the valve sleeve moves to the
g n
left. Through this movement, the opening
o
portion between the spool and the valve
block is slowly closed. The servo piston
in ti
a
stops moving when the opening portion is
completely closed.
et a
n
rk er
Ma t
In
ZX225-1102008
Adjustment value of the regulator
Type of regulator KR3G-0E11-AV

-1
Rotating speed (min ) 2050
Adjusting screw (954) screw-in (rotation) +1/4
Adjustment of max. flow
Flow rate change (L/min) -5.9
Adjusting screw (953) screw-in (rotation) +1/4
Adjustment of min. flow
Flow rate change (L/min) +4.7

4.5.1 Control valve
NOTE: For the location of the control valve on the machine, see “Hydraulic equipment layout” on
page 4-24.
(XAo) XBp2 XAa1
BaR XAa2
BoR
BkR
Psp
.
De al
BbR
pt
XAb1
Dr2
XBtr
XBtL
XAs
g no
XBtr
(PTa)
Dr3
in ti
PnA2
Dr6
et a
Dr7
Pns
n
rk er
Bs Btr As Atr
Pz AtL PX PG
PbL
MR
Ma t
TRAVEL STRAIGHT
Py TRAVEL RIGHT
XAtr
TRAVEL LEFT SWING
BtL Dr1
In
XAtL XBs
XBb1
BOOM1
Bb(Rod) SWING PRIORITY BOOM2
XAb2
AbR
BUCKET OPTION
XAk PCk AkR (XBo)

(Bo)
ARM2 ARM1
XBa2 XBk AoR Dr3 XBa1

(BYPASS CUT 1)
Bk(Rod) DR3 PCV1

(XBp1)
AaR
R2 Ba(Head)
PaL
Aa(Rod) Ak(Head) Ab(Head) (Ao)
P2 P1
R1
R1
ZX225-1102009

XAtr : R. travel (reverse) pilot port XBp2: Bypass cut spool pilot port (P2 side)
XBtr : R. travel (forward) pilot port XAb2: Boom confluence (UP) pilot pressure
(XAo): (Option pilot port) Psp: Swing priority pilot port
(XBo): (Option pilot port) R1: Return port
XAk: Bucket (DIG) pilot port R2: Oil feed port
XBk: Bucket (DUMP) pilot port Atr: R. travel motor port (reverse)
XAb1: Boom 1 (UP) pilot port Btr: R. travel motor port (forward)
XBb1: Boom 2 (DOWN) pilot port (Ao): Option
XAa2: Arm 2 (OUT) pilot port (Bo): Option
XBa2: Arm 2 (IN) pilot port Ak: Bucket cylinder head end port (DIG)
XAtL: L. travel (reverse) pilot port Bk: Bucket cylinder rod end port (DUMP)
.
XBtL: L. travel (forward) pilot port Ab: Boom cylinder head end port (UP)
De al
pt
XAs: Swing (left) pilot port Bb: Boom cylinder rod end port (DOWN)
XBs: Swing (right) pilot port
g n AtL: L. travel motor port (reverse)
XAa1: Arm 1 (OUT) pilot port BtL: L. travel motor port (forward)
o
XBa: Arm 1 (IN) pilot port As: Swing motor port (left swing)
Dr1: Drain port Bs: Swing motor port (right swing)
in ti
Px: Work equipment signal port Aa: Arm cylinder rod end port (OUT)
Py: Travel signal port Ba: Arm cylinder head end port (IN)
et a
Pz: Main relief valve boosting pressure P1: Pump port (P1 side)
n
PG: Pilot pressure resource port P2: Pump port (P2 side)
Pns: Swing logic control valve pilot port MR: Main relief valve
rk er
PCK: Bucket (DIG) stroke limit pilot port AR: Arm regeneration check valve
PnA2: Arm 2 logic control valve pilot port AbR: Port relief valve
Ma t
Dr2: Drain port BbR: Port relief valve

In
Dr3: Drain port AkR: Port relief valve

Dr6: Drain port BkR: Port relief valve
Dr7: Drain port AoR: Port relief valve
Pal: Lock valve pilot port (arm rod end) BoR: Port relief valve
PbL: Lock valve pilot port (boom head end) AaR: Port relief valve
(XBp1):Bypass cut spool pilot port (P1 side) BaR: Port relief valve
NOTE: For more technical information about the control valve, see “Control valve” on page 3-6.

Hydraulic circuit diagram (with bucket confluence function)
P2 (P3) R1 (P0) P1 PG
d1 d2 d3
ĭ0.7 ĭ0.7 ĭ0.7
MR
CMR2
CMR1
Pz
TRAVEL R XBtr
(PTa) TRAVEL
XAtr STRAIGHT
Px
Atr CPG
Btr
CP1
Dr2
Dr6 LCs Py
XBs
SWING 4-ĭ2.1 XBtl TRAVEL L
XAs XAtl
.
De al
As Btl
Bs Atl
C2
pt
Pns Dr1
SWING
PRIORITY Psp LCb
XBb1
g n XAb1 BOOM1
BOOM2XAb2 Bb
o
AbR (ROD)
BbR
in ti
CCb
Ab
(HEAD)
HVb
PbL
LCk
et a
LCo
PCk
(XBo)
XBk
n
OPTION (XAo)
BUCKET
XAk
AoR
rk er
(Ao) BkR (ROD)

(Bo) Bk
Ak
AkR (HEAD)
BoR
AR
PnA2
Dr3 Dr7
Ma t
LCa LCAT2
2-ĭ1.0 LCAP2
2-ĭ2.0
In
XAa1 XBa2
ARM2
ARM1 XBa1 XAa2
(HEAD)
AaR
Ba
BaR
Aa
CCo
(ROD)
HVa
CCk PaL
BYPASS (XBp1)
CUT R2
XBp2
(P5)
ZX225-1102010

4.5.2 Operating principle
4.5.2.1 When spool is in neutral position
[Main circuit]
● When all the spools are in neutral position, ● Working oil supplied from the hydraulic
working oil supplied from the hydraulic pump (Rear) flows in through pump port P2
pump (Front) flows in through pump port and is introduced into the main passage
P1 and is introduced into the main pas- (3). It passes the neutral bypass (2) (neutral
sage (1). It passes the neutral bypass (2) M-shaped spool mechanism) of the spools
(neutral M-shaped spool mechanism) of of R travel (301), swing (305), boom con-
the spools of straight travel (308), L. travel fluence (boom 2: 307), option (309), arm 1
.
(301), boom 1 (303), bucket (304) and arm (302), and flows back into the working oil
De al
2 (306), and flows back into the working oil tank via return port (R1).
pt
tank via return port (R1).
g no
in ti
et a
n
rk er
Ma t
In

(1)
(2)
(PTa)
XAtL XBtL
XBb1 XAbL
XAk PCk
X8k
XBa2 XAa2
.
De al
pt
CCo CCk
P2 (P3)
g no
(3)
R1
(2)
XBtr XAtr
in ti
XAs XBs
et a
Psp XAb2
n
rk er
(XAo) (XBo)
XAa1 XBa1
Ma t
XBp2 (XBp1)
In
ZX225-1102011

4.5.2.2 Travel
[Pilot circuit] ● Likewise, when pressure at port XBtr for

the right travel spool (301) rises, neutral
● When the left or right travel spool is bypass (2) at arm 1 side is closed, and
switched, the side bypass circuit is closed working oil supplied from the hydraulic
and pressure at port Py (travel signal port) pump (rear) is introduced into the right
rises. travel motor via port Btr.
[Main circuit] ● On the other hand, return oil from the left
● When pressure at pilot port XBtL for left and right travel motor passes the left (right)
travel spool (301) rises, neutral bypass (2) travel spool via port Atl (Atr), and returns to
at boom 1 side is closed, and working oil working oil tank via return port (R1).
.
supplied from the hydraulic pump (front) is
De al
● The principle is the same when travel on
introduced into the left travel motor via port
pt
the opposite side is operated (when pres-
Btl. g n sure at pilot port XAtr and XAtl rises).
o
in ti
XAtr XBtr
et a
n
rk er
Ma t
In
Atr Btr
Travel motor
ZX225-1102012

4.5.2.3 Arm
(1) Arm OUT
[Pilot circuit] ● On the other hand, working oil from port

P1 is introduced into neutral bypass (2) via
● When the arm 2 spool (306) is switched, main passage (1). Neutral bypass is cut off
the side path is closed and pressure at port by switching the arm 2 spool (306). There-
Px (work equipment signal port) rises. fore, working oil in the parallel passage
[Main circuit] pushes open the logic cone valve (256-101)
of the arm 2 logic valve GP, and working oil
● When arm OUT is operated, pilot pres- from neutral bypass pushes open the cone
sure oil is supplied into port XAa1 and port valve (511) of the check valve and flows
.
XAa2. When pilot pressure oil is applied at
De al
into the arm 2 spool (306) via the U pas-
the two sides of port XAa1 and port XAa2,
pt
sage. Then, it merges with port As via the
arm 1 spool and arm 2 spool are switched inner passage of arm 2 spool (306) and is
to the left as shown in the illustration. As
g n supplied into the arm cylinder rod end (R).
a result, working oil from P2 is introduced
o
into neutral bypass (2) via main passage ● Return oil from the arm cylinder head end
(3). Neutral bypass is cut off by switching (H) via port Ba flows into the tank circuit of
in ti
arm 1 spool (302). Therefore, working oil arm 1 and arm 2, and returns to working oil
in the parallel passage pushes open the tank via tank port (R1).
cone valve (511) of the check valve, and
et a
flows into the arm 1 spool (302) via the U

n
passage. Then, it flows into the periphery

of arm 1 spool (302) and arm 2 spool (306)
rk er
and is supplied into the arm cylinder rod

end (R) via port As.
Ma t
In

R H
Aa 256-101
511
.
De al
pt
g no
XAa2
in ti
et a
n
rk er
XAa1
Ma t
In
Ba
511
ZX225-1102013

(2) Arm IN
[Pilot circuit] from neutral bypass pushes open the cone

valve (511) of the check valve and flows
● When the arm 2 spool (306) is switched, into the arm 2 spool (306) via the U pas-
the side path is closed and pressure at sage. Then, it merges with port Ba via the
port Px (work equipment signal port) rises. inner passage of arm 2 spool (306) and is
At the same time, pressure oil is supplied supplied into the arm cylinder head end (H).
to port PaL and the release signal of lock
valve option set (252) is sent out. ● On the other hand, pressure of the return
oil from the arm cylinder rod end (R) rises
[Main circuit] under the weight the arm, and the return
● When arm In is operated, pilot pressure oil oil returns to port Aa. Working oil that re-
is supplied to port XBa1 and port XBa2. turns to port Aa flows into the inside of the
.
De al
When pilot pressure oil is applied at the valve spool via the holes on the periph-
pt
two sides of port XBa1 and port XBa2, ery of the arm 1 spool (302), and pushes
arm 1 spool and arm 2 spool is switched to
g n open the cone valve (302-317) in the spool
the left. As a result, working oil from P2 is only under light load. It merges with port
introduced into the neutral bypass (2) via Ba through the holes on the spool. This is
o
main passage (3). Neutral bypass is cut off called the regeneration function of the arm.
in ti
by switching arm 1 spool (302). Therefore, ● If the pressure at the arm cylinder head
working oil flown into the parallel passage end and in the U passage rises, arm re-
pushes open the cone valve (511) of the generation check valve spool (257-211)
et a
check valve and flows into the arm 1 spool switches to the left. And, at the same time,
(302) via the U passage. Then, it flows into
n
the back pressure of the cone valve (302-

the periphery of arm 1 spool (302) and is 317) in the spool is closed. Therefore,
rk er
supplied into the arm cylinder head end (H) arm regeneration function is released and
via port Ba. return oil from the arm cylinder rod end
● On the one hand, working oil from port P1 (R) flows into the spool via the hole (a) on
Ma t
is introduced into neutral bypass (2) via the periphery of arm 1 spool (302). Then,
In
main passage (1). Neutral bypass is cut off it flows into arm regeneration check valve
by switching the arm 2 spool (306). There- set (257) via hole (c) on the periphery of
fore, working oil in the parallel passage arm 1 spool (302), and returns to the work-
pushes open the logic cone valve (256-101) ing oil tank via tank port R1.
of the arm 2 logic valve GP, and working oil

● Light load
Arm weight
R H
.
De al
Aa
pt
g no
in ti
XBa2
et a
n
rk er
(302-317)
XBa1
Ma t
In
(b)
(a) Ba
ZX225-1102014

● When pressure at arm cylinder head end (H) rises
R H
.
De al
pt
Aa
g no
in ti
XBa2
et a
n
rk er
(302-317)
XBa1
Ma t
In
(c)
(257-211) Ba
(a)
ZX225-1102015

4.5.2.4 Boom
(1) Boom UP
[Pilot circuit] ● At the same time, pilot pressure oil is also

supplied to port XAb2 and boom 2 spool
● When the boom 1 spool (303) is switched, (307) moves to the right. Working oil from
the side path is closed and pressure at port port P2 is introduced into neutral bypass.
Px (work equipment signal port) rises. Neutral bypass is cut off by switching the
[Main circuit] boom 2 spool (307). Therefore, working
oil in the parallel passage flows into boom
● When boom UP is operated, pilot pressure 2 spool (307) via the U passage. Then, it
oil is supplied into port XAb1 and boom 1 pushes open the cone valve (511) of the
spool (303) moves to the left. Working oil check valve and merges with port Ab and
.
De al
from port P1 is introduced into neutral by- is supplied into the boom cylinder head
pt
pass (2) via main passage (1). Neutral by- end (H). This is called the boom conflu-
pass is cut off by switching boom 1 spool
g n ence function.
(303). Therefore, working oil in the parallel
passage pushes open the cone valve (511) ● On the other hand, return oil from the
o
of the check valve, and flows into the boom boom cylinder rod end (H) via port Bb flows
into the periphery of boom 1 spool (303)
in ti
1 spool (303) via the U passage. Then, it
flows into the periphery of boom 1 spool and returns to the working oil tank via tank
(303) and is supplied into the boom cylin- port (R1).
et a
der head end (H) via port Ab.

n
rk er
Ma t
In

H R
511
Ab
Bb
.
De al
pt
g no
XAb1
in ti
XAb2
et a
n
rk er
Ma t
In
511
ZX225-1102016

(2) Boom DOWN
[Pilot circuit] passage. Then, it flows into the periphery

of boom 1 spool (303) and is supplied into
● When the boom 1 spool (303) is switched, the boom cylinder rod end (R) via port Bb.
the side path is closed and pressure at
port Px (work equipment signal port) rises. ● On the other hand, return oil from the
At the same time, pressure oil is supplied boom cylinder head end (H) passes the
to port PbL and the release signal of lock hole (a) and the periphery of boom 1 spool
valve option set (252) is sent out. (303).
[Main circuit] ● Return oil pressure rises due to the self

weight of the boom. Cone valve (303-317)
● When boom DOWN is operated, pilot pres- in the spool is pushed to the right. Return
sure oil is supplied to port XBb1. Boom 1 oil flows to the outside of spool. The pres-
.
De al
spool (303) moves to the right. As a result, sure oil is supplied into the boom cylinder
pt
working oil from P1 is introduced into the rod end (R) as the working oil for boom
neutral bypass (2) via main passage (1).
g n DOWN operation. This is called the boom
Neutral bypass is cut off by switching boom regeneration function. Part of the oil that
1 spool (303). Therefore, working oil flown flows into the inside passage of the spool
o
into the parallel passage pushes open the via hole (a) returns to the working oil tank
in ti
cone valve (511) of the check valve and via hole (b).
flows into the boom 1 spool (303) via the U
et a
n
rk er
H R
Ma t
In
511
Ab Bb
XBb1
(b) (a)
(303-317)
ZX225-1102017

4.5.2.5 Bucket
(1) Bucket DIG

[Pilot circuit] Then, it flows into the periphery of bucket
spool (304) and is supplied into the bucket
● When the bucket spool (304) is switched, cylinder head end (H) via port Ak.
the side path is closed and pressure at port
Px (work equipment signal port) rises. At ● On the other hand, return oil from the buck-
the same time, pressure oil is supplied at et cylinder rod end (R) flows in via port Bk.
port XBp2. Then, it flows to oil tank port (R1) via the
spool periphery and returns to working oil
[Main circuit] tank.
● When bucket DIG is operated, pilot pres- ● When boom UP and bucket DIG are oper-
.
sure oil is supplied into port XAk and buck-
De al
ated simultaneously, pilot pressure oil is
et spool (304) moves to the right. Working
pt
supplied to port Pck. Therefore, the stroke
oil from port P1 is introduced into neutral of bucket spool is not limited at stroke end,
bypass (2) via main passage (1). Neutral
g n
bypass is cut off by switching bucket spool
but on any position halfway. As a result,
bucket cylinder passage is throttled and
o
(304). Therefore, working oil in the paral- working oil flows into boom 1 spool (303)
lel passage pushes open the cone valve
in ti
via bucket spool (304). In this way, boom
(511) of the check valve, and flows into UP operation takes precedence.
the bucket spool (304) via the U passage.
et a
n
rk er
H R
Ma t
In
Ak Bk
H
XAk
Pck
ZX225-1102018

(2) Bucket DUMP
[Pilot circuit] tral bypass is cut off by switching bucket

spool (304). Therefore, working oil in the
● When the bucket spool (304) is switched, parallel passage pushes open the cone
the side path is closed and pressure at port valve (511) of the check valve, and flows
Px (work equipment signal port) rises. At into the bucket spool (304) via the U pas-
the same time, pressure oil is supplied at sage. Then, it flows into the periphery of
port XBp2. bucket spool (304) and is supplied into the
[Main circuit] bucket cylinder rod end (R) via port Bk.
● When bucket DUMP is operated, pilot ● On the other hand, return oil from the buck-
pressure oil is supplied into port XBk and et cylinder head end (H) flows in via port
bucket spool (304) moves to the left. Work- Ak. Then, it flows to oil tank port (R1) via
.
the spool periphery and returns to working
De al
ing oil from port P1 is introduced into neu-
oil tank.
pt
tral bypass (2) via main passage (1). Neu-
g no
H R
in ti
et a
n
Ak Bk
rk er
XBk
Ma t
In
ZX225-1102019
(3) Bucket confluence
● When bucket DIG is operated, pilot pres- switching neutral bypass valve spool (310).
sure oil is supplied into port XBp2 and the Therefore, working oil pushes open the
neutral bypass cutoff valve spool (310) is check valve, and interconnects with the U
switched. Working oil from port P2 is in- passage via the inside path, and converg-
troduced into neutral bypass (2) via main es with bucket spool (304).
passage (3). Neutral bypass is cut off by

4.5.2.6 Swing
(1) Swing operation
[Pilot circuit] (305). Therefore, working oil in the parallel

passage pushes open the logic cone valve
● When the swing spool (305) is switched, (2540-101) of the swing logic valve GP,
the side path is closed and pressure at port and flows into the swing spool (305) via the
Px (work equipment signal port) rises. U passage. Then, it flows into the periph-
[Main circuit] ery of swing spool (305) and is supplied
into the swing motor via port As (or Bs).
● When swing is operated, pilot pressure
oil is supplied into port XAs (or XBs) and ● On the other hand, return oil from the
swing spool (305) is switched. Working swing motor flows in via port Bs (or port
.
As). Then, it flows into tank port (R1) via
De al
oil from port P2 is introduced into neutral
the spool periphery and returns to the
pt
bypass is cut off by switching swing spool
g n working oil tank.
o
XBs XAs
in ti
et a
n
rk er
Ma t
As Bs
In
(254-101)
Swing motor
ZX225-1102020

(2) Swing priority function
[Pilot circuit] ● Switch swing priority spool (311). The

opening area of the swing priority reduces.
● Pilot pressure oil is supplied to port Psp As a result, working oil from arm 1 spool
and swing priority spool (311) is switch. (302) flows into swing spool (305) and
[Main circuit] swing operation takes precedence.
.
De al
Psp
pt
g no
in ti
et a
ZX225-1102021
n
rk er
Ma t
In

4.5.2.7 Option
Option spool is used to control optional work equipment attachment.
(1) Operation
[Pilot circuit] (309). Therefore, working oil in the parallel
passage pushes open the cone valve (511)
● When the option spool (309) is switched, of the check valve, and flows into the op-
the side path is closed and pressure at port tion spool (309) via the U passage. Then,
Px (work equipment signal port) rises. it flows into the periphery of option spool
[Main circuit] (309) and is supplied into the optional
equipment via port Ao (or Bo).
● When option is operated, pilot pressure
oil is supplied into port XAo (or XBo) and ● On the other hand, return oil from the op-
.
De al
option spool (309) is switched. Working tional equipment flows in via port Bo (or
pt
oil from port P2 is introduced into neutral port Ao). Then, it flows into tank port (R1)
g n via the spool periphery and returns to the
bypass is cut off by switching option spool working oil tank.
o
XAo
in ti
XBo
et a
n
rk er
Ma t
In
Ao Bo
ZX225-1102022
(2) Option confluence Neutral bypass is cut off by switching by-

pass valve spool (310). Therefore, work-
● To achieve option confluence, pilot pres- ing oil pushes open the cone valve (514)
sure oil is supplied into port XBp1 and the of check valve, and converges with option
bypass cutoff valve spool (310) is switched. spool (309) via the inside path and the U
Working oil from port P1 is introduced into passage.
neutral bypass (2) via main passage (1).

4.5.2.8 Travel straight
When travel spool (301) and other spool are [Main circuit]
operated simultaneously.
● When straight travel spool (308) is
The following case shows when travel spool switched, the right/left travel spool (301)
(301) and swing spool (305) are operated si- are interconnected with port P2. The paral-
multaneously. (When pilot pressure oil is sup- lel passage of swing/boom 2/option/arm
plied to port XAtL, port XAtr and port Xas) 1 circuit and boom 1/bucket/arm 2 circuit
are interconnected with port P1. Therefore,
[Pilot circuit] working oil supplied from port P2 flows into
● The side path of right/left travel spool (301) port Atl and port Atr, and is supplied to the
and the side path of the swing spool (305) two travel motors equally.
at the downflow side are closed.
.
● On the other hand, working oil from port P1
De al
is supplied to the swing motor via port As.
pt
● Pilot oil from port PG is supplied to port
PTa and straight travel spool (308) is
g n ● When oil pressure at port P2 is lower than
switched. that at port P1, part of the working oil form
port P1 is supplied to port P2. In this way,
o
sharp decrease of travel speed is averted.
in ti
et a
P1 P2
n
rk er
PTa
Ma t
In
ZX225-1102023

4.5.2.9 Lock valve function
● The lock valve option set (252) is installed ● When boom 1 spool (303) is in neutral po-
between the arm cylinder rod end (R) and sition, spool (252-511) in the lock valve op-
arm 2 spool (302) and arm 2 spool (306). tion set is pressed against the valve seat
It is used to reduce the internal leakage of of the valve sleeve (252-541) inside the
the spool due to cylinder pressure. lock valve option set, as shown in the illus-
tration, via the spring force of spring (252-
● Likewise, lockout option set (252) is also 321).
installed between boom cylinder head end
(H) and boom 2 spool (303) to reduce the ● At this position, working oil at the boom
internal leakage of he spool due to cylinder cylinder head end (H) flows in via hole (a)
pressure. and flows out from hole (b) through the
periphery of the lock valve option set spool
.
De al
(1) Spool in neutral position (252-511), pressing the cone valve (513)
pt
● The following shows when boom 1 spool against the valve seat of the valve block
(303) is in neutral position. (The same is via hole (b). By this means, oil leakage is
g n
with arm 2 spool (306))
o
reduced.
in ti
252-321 252-511
252-541
et a
n
(b)
rk er
513
Ma t
(a)
In
ZX225-1102024

(2) Boom DOWN operation
● When boom DOWN is operated, pilot pres- into spring chamber (RH). In addition, oil
sure oil is supplied to port PbL and port in the spring chamber (RH) flows into drain
XBb1. Spool (252-511) inside the lock circuit via hole (b). In this way, the cone
valve option set moves to the top by via pi- valve (513) is pushed up by the pressure
lot pressure oil. Through the movement of at boom cylinder head end (H) and the
spool (252-511) inside the lock valve option function of the lock valve option set (252)
set, hole (a) is cutoff and working oil from is released.
boom cylinder head end (H) does not flow
252-511
.
De al
(b) (RH)
pt
g n 513
(a)
o
PbL
in ti
et a
n
rk er
XBb
Ma t
In
ZX225-1102025
(2) Boom UP operation
● When boom DOWN is operated, pilot pres- boom 1 spool (303) and working oil flows
sure oil is supplied to port XAb1. The cone into port Ab.
valve (513) is pushed ope by the oil from

4.5.2.10 Main relief valve function
The main relief valve is installed on the valve and enters low-pressure path (R).
block A (101). Its function is described below:
● Opening of cone valve (611) causes pres-
● Working oil flows into chamber (a) from sure in chamber (a) to drop and valve rod
passage (P) via the hole of valve seat (541) (512) is open. In this way, working oil in
and hole on valve rod (512). Valve rod (512) passage (P) flows into low-pressure path
is pressed against valve seat (541), form- (R) directly.
ing a tight seal.
● When pressure oil high than 3MPa is sup-
● When pressure in passage (P) exceeds plied to port Pz, this pressure oil pushes
the elastic force of spring (621), cone valve plunger (614) to the left. The set load of
(611) is pushed open. Therefore, working spring (621) is changed and pressure of
.
oil flows through the hole on valve sleeve the main relief valve rises.
De al
(103) via the periphery of cone valve (611)
pt
g no
541 611 621
in ti
et a
n
P
rk er
R
Ma t
Pz
In
512 (a) 103 614

ZX225-1102026

4.5.2.11 Port relief valve function
The port relief valve is installed between the

tank port and low-pressure path. In addition
to the function as relief valve, it has also the
function of anti-cavitation oil complement
check valve. Its function is described below:
(1) Relief valve function
● Working oil flows into chamber (B) via the

hole (A) on plunger (301). Valve rod (511)
is pressed against valve seat (541), and
valve seat (541) is pressed onto the valve
.
seat of the valve block, forming a tight seal.
De al
pt
g n
B
o
A
in ti
et a
P
n
rk er
R
301 511 541
ZX225-1102027
Ma t
In
A B
301 R
511 541
ZX225-1102028

● When pressure in passage (P) exceeds

the elastic force of spring (621), cone valve
(611) is pushed open. Therefore, working
oil flows through hole (C) via the periphery
of cone valve (611) and enters low-pres-
sure path (R).
.
De al
pt
P
g no
R
611 621
in ti
ZX225-1102029
et a
n
C
rk er
Ma t
In
R
621
611
ZX225-1102030

● Opening of cone valve (611) causes pres-

sure in chamber (B) to drop and valve rod
(511) is open. In this way, working oil in
passage (P) flows into low-pressure path
(R) directly.
.
P
De al
pt
g n R
511 611
o
ZX225-1102031
in ti
B
et a
n
rk er
P
Ma t
R
In
511 611
ZX225-1102032

(2) Anti-cavitation oil complement check

valve
● When negative pressure is formed in path

(P), working oil is supplied from path (R).
When pressure in path (R) gets higher
than pressure in path (P), valve seat (541)
moves to the right direction. Therefore,
working oil is supplied from path (R) to
path (P) via the periphery of valve seat
(541) in order to prevent cavitation.
.
De al
pt
g nP
o
in ti
R
541 ZX225-1102033
et a
n
rk er
Ma t
In
R
541 ZX225-1102034

4.5.3 Section view
B A 273×10
153
(Po)
XAtr
561 TRAVEL
TRAVEL R STRAIGHTC
C 273×12 HR
XBs XAtl TRAVEL L

SWING 252
D D
Dr8 PnS XAb2 XBbl

BOOM1
BOOM2 977
978×2 E
E
.
De al
AbR
XAk
pt
XBo BUCKET
OPTION
F F
g n AoR AkR
XBa1 XBa2
ARM1 ARM2
G AR G
o
(BYPASS CUT1) (XBp1)
PnA2 Dr7
in ti
H BYPASS CUT2
O AaR O 252
PCV1 H AaR
602
A
et a
B
n
XBa2
(XBp1)
rk er
Dr3
View O-O
Ma t
In
274×4
CCo
Pns (P5)
Dr6 Dr7
PnA2
CCk P P
210
153 561
(P5)
Viw P-P
XAa2
273×12 XBk 273×10
XBp2 PCk
ZX225-1102035

Section A-A, N-N
N
543
101 159 541 542 166
550
(PTa)
.
De al
XAtL XBtL
pt
g n
XBb1 XAbL
o
in ti
XAk PCk
et a
XBk
n
XBa2 XAa2
rk er
Ma t
In
CCo CCk
514 521 561 551 551 561 521 514
View A-A
151 168 151 168 151

168
PB 156
2-156
View N-N
ZX225-1102036

Section B-B
153 561 102

P2 (P3) R1
975 975
XBtr XAtr
975
.
XAs
De al
XBs
pt
g n 975
Psp XAb2
o
975
in ti
(XAo) (XBo)
975 975
et a
XAb1 XBa1
n
975
rk er
XBp2 (XBp1)
Ma t
In
975
975
165 165 165
View B-B
ZX225-1102037

Section C-C (Travel right, travel straight)
154
164
201 TRAVEL TRAVEL 201
RIGHT STRAIGHT
336 336
332 XAtr 332
335 323
321 335
320
332
332
332 MR
.
De al
261
261
308
pt
163 601
314
g n
Pz
o
165
in ti
512
163 Atr 522
511 553
521
et a
551
n
CP1 CMR1
561 562
rk er
165 562
163
163 Btr
Ma t
CMR2
In
163
553
522
512
159
264 159
264
204
XBtr (PTa) 204
164
View C-C
154
ZX225-1102038

Section D-D (Swing, travel left)
201
SWING TRAVEL LEFT 336
201
336 332
XBs XAtL
332 335
335
321
321
320
320
332
261
332
.
314
De al
261
pt
305 g n
161
o
163
163 AtL
in ti
As
254 511
et a
521
C2
n
551
rk er
561
BtL
251
Ma t
Bs
In
165
Dr2
264
264
XAs XBtl
204
204
163 163
View D-D
ZX225-1102039

Section E-E, L-L (Boom 1, boom 2)
202 BOOM2 BOOM1

336 201
332 XAb2 XBb1 336
339 332
327 335
321
326
320
602
332
332 261
.
261
L L
De al
158
pt
161
511 Dr1
PbL
521
g no
523
CCb CRb 552

561
in ti
551
561 513
165 511
521
et a
307
LCb
163
n
Xb2
551
rk er
551 561
561
Bb
311
Ma t
In
161 303
163
264
261 602
332 XAb1 204
BbR
320
329 158
339
332
336
202 Psp
SWING
PRIORITY
View E-E View L-L
ZX225-1102040

Section F-F (Option, bucket)
259
164
201
201
OPTION BUCKET 336
336
(XBo) 332
332
335 335
321 321
320 320
602
332 AkR 332
.
De al
261 261
pt
604 304
163
g n
209
o
971×4
in ti
165 Ak
309
163 (Ao)
et a
163
511 511
n
521
521
LCo
rk er
551
551
561
Ma t
561
(Bo)
In
Bk
163
165
971×4
209
163
264 602
604 264
(XAo) 206
204 BkR
211
164 BoR XBk
561
154 258
PCk
View F-F ZX225-1102041

Section G-G (Arm 1, arm 2)
201
201 336
336
332
332 XBa1 XBa2
335
335
321 321
320 320
257 Dr3
AR 332
332
261
261
.
306
De al
L L
pt
158
163
165
g n 513
162 523
o
152 CRa 561
552
in ti
165
162 251
152
et a
302
511
521
n
rk er
551 LCAT2 256

561
551
Ma t
163 561
R2 521
In
511
165
163
264 264
602 XAa2
XAa1
BaR 204
205
View G-G
ZX225-1102042

Section H-H (Bypass cut 1, bypass cut 2)
612 169 162 152 158 154 164 152 162 162 152 164 154 158 152 162 164 154 169 612 162 152
PCV2 PCV1
XBp2
.
De al
(XBp1)
pt
g n
203 333 331 372 373 337 331 262 310 165 165 310 163 262 331 337 373 372 331333 203
o
View H-H
in ti
ZX225-1102043
et a
n
rk er
Ma t
In

Mounting Mounting
NO. Part name Q’ty NO. Part name Q’ty
torque (N·m) torque (N·m)
SPOOL ASS’Y, travel
101 BLOCK, valve A 1 308 1
straight
102 BLOCK, valve B 1 309 SPOOL, option 1
13~17 151 PLUG 3 310 SPOOL, bypass cut 2
34~39 152 PLUG 7 311 SPOOL, swing priority 1
220~250 153 PLUG 3 320 SPRING 9
69~78 154 PLUG 6 321 SPRING 8
7.4~9.8 156 PLUG, orifice 3 322 SPRING 1
7.5~10 158 PLUG 5 323 SPRING 1
10~14 159 PLUG 3 326 SPRING 1
.
De al
161 O-RING 3 327 SPRING 1
pt
162
g n O-RING 7 329 SPRING 1
163 O-RING 21 331 SPRING SEAT 4
164 O-RING 7 332 SPRING SEAT 22
o
165 O-RING 14 16~18 333 FLANGE SOCKET 2
in ti
166 O-RING 1 335 STOPPER 9

168 O-RING 3 16~18 336 FLANGE SOCKET 11
et a
169 O-RING 2 337 STOPPER 2

201 COVER, spring 9 339 STOPPER 2
n
202 COVER, spring 2 372 SPRING 2

rk er
203 COVER, spring 2 373 SPRING 2

204 COVER, spool 7 511 VALVE, cone 8
Ma t

In
209 FLANGE 2 514 VALVE, cone 2

210 PLATE 1 521 SPRING 10
211 PISTON 1 522 SPRING 2
49~65 251 VALVE, logic control 2 523 SPRING 2
OPTION ASS’Y, lock
9.8~14 252 2 541 BALL 1
valve
254 VALVE GP, swing logic 1 542 SPRING SEAT 1
256 VALVE GP, arm 2 logic 1 543 SPRING 1
CHECK VALVE ASS’Y,
69~78 257 1 25~29 550 PLUG 1
arm regeneration
258 PLUG 1 230~260 551 PLUG 11
259 PLUG 1 230~260 552 PLUG 2
261 O-RING 11 130~150 553 PLUG 2

Mounting Mounting
NO. Part name Q’ty NO. Part name Q’ty
torque (N·m) torque (N·m)
262 O-RING 2 561 O-RING 17
264 O-RING 9 562 O-RING 2
25~34 273 SCREW, hex, S,H,C 44 69~78 601 VALVE, main relief 1
98~120 274 SCREW, hex, S,H,C 4 69~78 602 VALVE, port relief 6
301 SPOOL, travel 2 120~140 604 VALVE, port relief 2
302 SPOOL ASS’Y, arm 1 1 69~78 612 PLUG 2
303 SPOOL ASS’Y, boom 1 1 49~65 971 SCREW, hex, S,H,C 8
304 SPOOL, bucket 1 140~180 975 SCREW, hex, S,H,C 10
305 SPOOL, swing 1 977 PLATE name 1
.
306 SPOOL, arm 2 1 978 PIN 2
De al
pt
307 SPOOL, boom 2 1
g no
in ti
et a
n
rk er
Ma t
In

4.6.1 Swing motor
NOTE: For the location of the swing motor on the machine, see “Hydraulic equipment layout” on
page 4-24.
.
De al
pt
g n L
SH PG
o
PB
B
in ti
IP
et a
PA A
n
rk er
1
M DR
Ma t
In
A: Main oil port

ZX215-1002081
B: Main oil port
M: Oil complement port 1. Relief valve
PA: Pressure detection port 2. Reverse prevention valve
PB: Pressure detection port
DB: Lubricating port For more technical information about the
PG: Brake release port swing motor, see “Swing motor” on page 3-6.
SH: Brake direction port
L: Oil level stick
IP: Gear oil feed port

7
6
.
De al
pt
A-A
g n
A
o
8 9
in ti
5
A
et a
4
n
10
rk er
Ma t
11
3
In
12
2
13
1
ZX215-1002082
(1) Spacer (6) Check valve spring (11) Plate

(2) Casing (7) Check valve (12) Piston
(3) Disc (8) Oil distribution plate (13) Drive shaft
(4) Brake spring (9) Cylinder
(5) Shell (10) Brake piston

4.6.2 Swing holding brake
● Port PG is connected with the pilot gear pump directly, and a pressure of 3.9MPa is main-
tained.
M
Pump a
1
Main valve
7
PX
.
De al
PG
pt
6
SH
g n
5
o
in ti
ZX215-1002083
● Port SH is connected with port PX of the main valve. Once any movement other than travel
et a
is applied on the main valve, pressure will be generated at port PX, and port PG is intercon-
nected with chamber a beneath piston 7. The pressurized oil compresses brake spring (1)
n
and pushes the brake piston up. Disc (5) is separated from plate (6), releasing the brake.
rk er
Ma t
In
M
Pump a
1
Main valve
7
PX
PG
6
SH
ZX215-1002084
● Otherwise, no pressure is generated at port PX, and port PG is shut off from chamber a be-
neath piston (7). Brake piston (7) is pushed down by brake spring (1). Disc (5) and plate (6)
are pushed together, and the brake is applied.

4.6.3 Relief valve portion
NOTE: For the location of the relief valve on

the swing motor, see “Swing motor” on page 4-81.
Structure
● The relief valve portion consists of relief

valves (1) and (2), check valves (3) and (4).
Function
● When the machine is in the swing holding

mode, control valve (5) closes the motor
outlet circuit, but the motor rotation contin-
.
De al
ues due to inertial force. The motor output,
pt
therefore, is abnormally increased, result-
ing in motor damage.g n
● In order to avoid the motor damage, the
o
relief valve relieves the abnormally high
pressure to port (M) from the motor outlet
in ti
side (high-pressure side) of the motor.

et a
n
rk er
Ma t
In

Operation
1. When swing begins (suppose pressur-

ized oil enters Port A) From port M
1 2
● When the swing control lever is operated
for right swing, pressurized oil from the
pump is supplied to port (A) via control
valve (5).
● The pressure on port (A) rises, the starting

torque is generated in the motor, and the
motor is activated. 4
3
● The pressurized oil from the outlet port of
.
De al
the motor passes from port (B) through the C
pt
control valve (5) and returns to the tank. A B
g n 5
ZX215-1002085
o
2. When swing stops
in ti
● When the swing control lever is neutral-

From port M
ized, the supply of pressurized oil from the 1 2
et a
pump to port (A) is cut off.

n
● The pressurized oil from the motor outlet

can't return to the tank since the return cir-
rk er
cuit to the tank is closed from control valve

(5). Thus, pressure at port (B) rises.
Ma t
● Swing resistance is generated on the mo-

tor and hence the brake starts working. 4
In
● Pressurized oil will be relieved when the

pressure on port (B) rises to the set pres- C
sure of relief valve (2). A B
● A high braking torque is applied on the mo- 5

tor, thereby stopping the motor. ZX215-1002086
● When relief valve (2) is being actuated, the

relieved pressurized oil and the pressur-
ized oil from port (M) are fed to port (B) via
check valve (4).
● Above prevents cavitation on port (B).

4.6.4 Reverse prevention valve
4.6.4.1 Operation drawing
NOTE: For the location of the reverse prevention valve on the swing motor, see “Swing motor” on
page 4-81.
A T1
.
De al
pt
g n T2 B
1 2 3 4
o
in ti
et a
7 6 5
n
Swing T
motor
rk er
B A
Swing control valve

Ma t
ZX215-1002087
In
(1) Valve body (5) Spool (B side)

(2) Spool (A side) (6) Spring (B side)
(3) Spring (A side) (7) Plug
(4) Plug

4.6.4.2 Explanatory drawing of effects
With reversal prevention valve
:Without reversal prevention valve

Reversal pressure
Pressure MA
Containment pressure
Reversal pressure
Pressure MB
.
1st reversal
De al
pt
2nd reversal
Motor speed
g no
Start Brake Reversal
in ti
Time
ZX215-1002088
et a
Outline
n
● Inertia of the swing body, the backlash and

rk er
rigidity of the machinery system, and the A

compression of the hydraulic oil all may T
c e D4 a D3
cause the machine to shake during swing
Ma t
operation. The reverse prevention valve is

In
designed to reduce this effect. The valve

contributes in preventing collapsing of load
when the swing is stopped and also con-
tributes in reducing cycle time (enhances
the positioning performance, enabling you
to proceed to the next work quicker than D1 d Notch D2 % b f
ever). 7
ZX215-1002089

Operation
1. When port (B) brake pressure is gener-

ated
● Pressure (MB) is conducted to chamber (d)

$
via the notch. The pressure compresses
T
spring (6) by use of the difference in areas F H ' D '
of circles (D1 > D2) of spool (5) and moves
spring (6) to the left side. Port (B) and
chamber (e) will be interconnected. Since
pressure (A) is lower than the set pressure
of spring (3), spool (2) does not move and
the pressurized oil is stopped by spool (2).
.
Thus the braking force is ensured.
De al
' G Notch '
pt
E I
%
g n T
ZX215-1002090
o
2. When motor is stopped
in ti
● The motor rotation is reversed by the clos- A

ing pressure generated at port (B). (1st T
et a
time: reverse rotation) Reversing pressure a 2 3

is generated on port (A). Pressure (A) is
n
conducted to chamber (a), and spool (2)

rk er
moves spring (3) to the right side, and A

and B is interconnected. At this time, b
is interconnected with f via the orifice on
Ma t
spool (5), and reversing pressure on port A

is bypassed to port T, preventing the sec-
In
5 d B b f
ond reverse rotation.
T
ZX215-1002091

4.6.5 Center swivel joint
NOTE: For the location of the central swivel joint on the machine, see “Hydraulic equipment lay-
out” on page 4-24.
Z
7 8 13 9 10
6 H
11
5 12
4 D
.
De al
C
pt
B
A
g no
3
2
in ti
F1
et a
n
G1 H-H H
G
rk er
D1
Ma t
A1
In
B1
C1
Z
ZX215-1002092
(1) Swing shaft (8) Plug (ZG3/4)

(2) Dust seal (9) Plug (ZG1/4)
(3) O-ring (10) Cover
(4) Swing body (11) Spacer
(5) Rotating seal φ100x5 (12) Gasket
(6) Gasket (13) Gasket
(7) Retaining ring φ 90

A: From main valve BTL

B: From main valve BTR
C: From main valve ATL
D: From main valve ATR
A1: To L. travel motor port (P1)
B2: To R. travel motor port (P2)
C3: To L. travel motor port (P2)
D4: To R. travel motor port (P1)
G: To swing motor port DB
G1: From travel motor final drive assembly oil drain port (D1,D2)
F: From solenoid valve port A2
.
F1: To travel motor reducer Hi/Lo speed switching port (P)
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

4.6.6 Travel motor
Model: TM40VD-A-99/163-1
NOTE: For the location of the travel motor on the machine, see “Hydraulic equipment layout” on
page 4-24.
D1
.
P P1
De al
pt
g n P2 B
D2
o
P5
in ti
WX215-1204014G
Ps: Duo speed pilot hose port D1: Drain port

et a
P1: Pressure detection port D2: Plug

n
P2: Pressure detection port A: Main oil port

P5: Parking brake release port B: Main oil port
rk er
Working condition
Ma t
Speed 1 Speed 2
In
Gear ratio 49.95

Reduction gear Theoretical output torque (kgf.m) Max. 4650 4535 2767
Theoretical output speed (r.p.m) Max. 60 28 45.9
Displacement (cc/rev) Max. 174.7 162.9 99.4
Continuous pressure (kgf/cm2) Max. 350 350
Theoretical speed (r.p.m) Max. 2800 1400 2294
Hydraulic motor Flow (l/min) 250 228
Duo speed control pressure (kgf/cm2) 20~70
Braking torque (kgf.m) Min. 50
Brake release pressure (kgf/cm2) 8.2
1~3L/min (above 365)
Relief valve activation pressure
15L/min (above 420)

Explosive view
37
38
46 43 50
42
15 40
41
5 1
10 44
8 22
6 34
11 35 47
14 48
21 49
3 19 33
9 7
42
.
15 4 27
20
De al
21 6 30
23 24
8 29
pt
14 10
5 31
15
32
18 15
17 54
12 55
g n 25 52
51
2
4
7
28
36
39
56
9
o
58 45
57 3
26
53 59
in ti
13
16
WX215-1204013G
et a
(1) Flange, rear (16) Plug (31) Baffle (46) Ball bearing
n
(2) H5 balance valve (17) Spool (32) Spheric bush (47) Spring
rk er
spool (18) Spring (33) Timing plate (48) Piston

(3) Plug (19) Ball (34) Parking piston (49) Stopper
(4) D type block (20) Orifice (35) Spring (50) Pivot
Ma t
(5) Check plug (21) O-ring (36) C y l i n d e r b l o c k (51) Plunger

In
(6) Check valve (22) Filter spring (52) Piston seal

(7) Spring (23) Name plate (37) Friction plate (53) Valve body
(8) Stop spring (24) Rivet (38) Spacer (54) Washer
(9) O-ring (25) Plug (39) Oil seal (55) O-ring
(10) O-ring (26) Drive shaft (40) O-ring (56) O-ring
(11) Parallel pin (27) P - t y p e s w a s h (41) O-ring (57) Shim
(12) Socket head bolt plate (42) Parallel pin (58) Spring
(13) O-ring (28) Cylinder block (43) Washer (59) Piston rod
(14) Plug (29) Piston (44) Washer
(15) Plug (30) Stopper (45) Ball bearing

Model: MAG-170VP-3400E
NOTE: For the location of the travel motor on the machine, see “Hydraulic equipment layout” on
page 4-24.
Ps Pm1 Tin 1 Dr P1 A
.
De al
pt
g no
in ti
Pm2 Pp 2 P2 B
ZX215-1002132
et a
n
Ps: Duo speed pilot hose port A. Mounting surface with sprocket
Pm1: Pressure detection port B. Mounting surface with undercarriage
rk er
Pm2: Pressure detection port 1. Mounting hole with sprocket

Tin: Motor case inner oil port 2. Mounting hole with undercarriage
Ma t
Pp: Brake release port

In
Dr: Oil drain port

P1: Main oil port
P2: Main oil port
NOTE: For more technical information about the travel motor, see “Travel motor” on page 3-7.

Connected to sprocket
Mounted on the undercarriage 5 4 2-1 1-4 1-3
Piston motor shaft

1-5
.
De al
pt
1-6
g n
1-2
o
in ti
1-1
et a
n
rk er
3
Ma t
In
2-4 2-3 2-2 2-6 2-5

ZX215-1002093

4.6.6.1 Operation of components
Counterbalance valve
Function
● When external load makes the rotating

speed of the piston motor faster than the
rated rotating speed of supplied delivery,
this valve controls the speed of the motor
and prevent over-speed of the motor in re-
lation with the supplied delivery.
● The counterbalance valve and the relief

valve constitute the braking circuit. The
.
De al
braking circuit applies braking force onto
pt
the rotating motor and stops the motor
gradually. g n
● This valve can serve as a shuttle valve
o
for high pressure selection to release the
brake under its own pressure.
in ti
● The structure of a standard counterbalance

valve is shown as below. The following in-
et a
formation describes the operating principle

of a standard counterbalance valve.
n
rk er
Ma t
In

A. Stopped state
● When the main valve is neutralized (motor pressure is generated at port P1 and port
stopped), port M1 and port M2 are shut off P2. The motor is not rotating.
by spool (1) and check valve (2) since no
8-1
.
De al
8-2
Circuit B
pt
Circuit C2
Circuit C1
g n M1 M2
Orifice D3
o
Orifice D1
Damper chamber A2
in ti
Damper chamber A1
Orifice D4
Orifice D2
Spring chamber 2
et a
Spring chamber 1
n
P1 P2
6-1 6-2
rk er
7-1 7-2
Ma t
5-1 3 4-1 2-1 1 2-2 4-2 5-2

In
ZX215-1002094

B. When the motor is activated
● When hydraulic oil from the main pump damper chamber (A1) via orifice (4-1) and
enters port P1 of the counterbalance valve, check valve (5-1). The force generated in
spring (3) is pushed to the left by check this way pushes spring (7-2) on the other
valve (2-1), opening circuit C1. The hy- side and moves piston (1) to the right. At
draulic oil enters the piston motor via port this time, return oil from port M2 passes
M, trying to make the motor rotating. At the through circuit of the notch on the periph-
same time, return oil from the piston motor ery of piston (1), and through port P2 when
enters the counterbalance via port M2, but pressure is generated at port M2, and en-
it is stopped by check valve (2-2). The out- ters the tank via the main valve finally. The
put pressure of the main pump increases motor is activated at this time.
as a result, and the hydraulic oil works
.
on the inside of spring chamber (1) and
De al
pt
g no
8-1
in ti
8-2
et a
Circuit B
n
Circuit C2
Circuit C1
rk er
M1 M2
Orifice D3
Orifice D1
Damper chamber A2
Damper chamber A1
Ma t
Orifice D4
Orifice D2
In
Spring chamber 2
Spring chamber 1
P1 P2
6-2
6-1
7-1 7-2
5-1 3 4-1 2-1 1 2-2 4-2 5-2

ZX215-1002095

C. Counterbalance function
● When the engine runs at an excessively

high speed because of external force ap-
plied on it, the motor may lose control. At
this time, port P1 serves as the inlet side,
and the pressure drops. Pressure in spring
chamber 1 and damper chamber A1 also
drop. As a result, pison (1) moves to the
left under the force of spring (7-2), closing
circuit B. Circuit at the suction side is also
closed at the same time when the circuit
at return side is closed. When circuit B is
.
closed, pressure at port P1 rises due to
De al
hydraulic oil from the main pump, moving
pt
piston (10 to the right again. In this way,
when external load generates pump effect,
g n
slight movement of piston (1) keep circuit
o
B open. The rotation speed of the motor
keeps in line with fuel supply of the main
in ti
pump, and the motor will not lose control

because of the vacuum in the hydraulic
system.
et a
n
rk er
Ma t
In

D. Braking of motor
● The counterbalance valve and the relief braking force of motor rotation. When the
valve forms the braking circuit. When the pressure at port M2 reaches the set pres-
main valve is neutralized position, hydrau- sure of relief valve (8), cone valve (8-1) at
lic oil from the main pump is cut off, and port M1 overcomes the force of spring (8-
pressure at port P1 and P2 is the same. 2) and moves to the left, and hydraulic oil
As a result, piston (1) moves to the neutral flows the port M1. In this way, the impact-
position, and the opening area of circuit B ing force due to inertia at port M2 is under
decreases. At the same time, because of control, and vacuum at port M1 is avoided.
the inertia of external force, the motor does
not stop rotating (pump effect), and pres-
sure at port M2 rises and serves as the
.
De al
pt
g no
8-1
in ti
8-2
et a
Circuit B
Circuit C2
n
Circuit C1 M1 M2
Orifice D3
rk er
Orifice D1
Damper chamber A2
Damper chamber A1
Orifice D4
Ma t
Orifice D2
Spring chamber 2
In
Spring chamber 1
P1 P2
6-1 6-2
7-1
7-2
5-1 3 4-1 2-1 1 2-2 4-2 5-2
ZX215-1002096

E. Shuttle valve function for high pressure

selection
● The counterbalance valve can function ber E to release travel brake. In addition,
as a shuttle valve to release travel brake. piston (1) moves to neutral position, as
When hydraulic oil is fed to port P1, piston shown in fig 5 when motor stops. Circuit D
(1) moves to the right, as shown in fig. 4. is closed and drain circuit F of motor body
At this time, drain circuit F of motor body is connected. Hydraulic oil in travel brak-
is cut off, and circuit D leading to cylinder ing cylinder chamber E is conducted to the
chamber E for travel braking is connected. drain circuit of motor body, and travel brake
Hydraulic oil flows to circuit G via the ori- is applied.
fice, and enters travel brake cylinder cham-
.
De al
1
pt
Circuit D
g no
Circuit D
in ti
Orifice
Circuit F
Circuit F
Circuit D Circuit G Circuit G
Cylinder chamber E
et a
n
rk er
ZX215-1002097
1
Ma t
Circuit D
In
Circuit D
Orifice
Circuit F
Circuit F
Circuit D Circuit G Circuit G Cylinder chamber E
ZX215-1002098

Operation of parking brake
1) When travel begins
● As the travel lever is operated, pressurized

oil from the pump activates counterbalance
10
valve spool (10), opens the parking brake
circuit, and flows to chamber A of brake
piston (12). Pressurized oil overcomes the
force of spring (11) and pushes piston (12)
toward the left.
● Since the pushing force to plate (13) and
.
disc (14) disappears, plate (13) is sepa-
De al
Travel control valve
rated from disc (14) and the brake is re-
pt
leased.
A M
g n 11 14 13 12 22
ZX215-1002099
o
in ti
2) When travel stops
● As the travel lever is placed in neutral,

et a
counterbalance valve spool (10) returns to

10
the neutral position and closes the park-
n
ing brake circuit. The pressurized oil in

rk er
chamber (A) of brake piston (12) passes

through the orifice of the brake piston and
is drained to the motor case. Brake piston
Ma t
(12) is pushed to the right by spring (12).

Plate (13) and disc (14) are pushed to-
In
gether, and the brake is applied. As brake Travel control valve
piston (12) returns, flow of pressurized oil

is reduced with slow return valve (22). The
A M
time delay will be set to activate the brake 11 14 13 12 22
ZX215-1002100
only after the machine has stopped.

Brake valve operation
● The brake valve consists of suction safety

valve (8A) and counterbalance valve (18). Travel control valve
Functions and operations of respective PA PB
components are described below.
8A
18
.
De al
pt
MA MB
g no ZX215-1002101
1) Counterbalance valve and check valve

in ti
Function
● When the machine is travels downhill, the

et a
weight of the machine tends to make the Travel control valve

travel speed faster than the motor speed.
n
PA PB
If the machine travels with the engine at 8B
rk er
low speed, the motor may rotate at zero

8A
load, resulting in run away and inviting a
very dangerous situation. These valves are
Ma t
used to avoid such a situation by control-

ling the machine to travel as per the engine
In
speed (pump delivery).
19 MA MB
Operation when pressurized oil is supplied
ZX215-1002102
● Operating the travel lever conducts the
pressurized oil from the control valve to
port (PA). The pressurized oil opens suc-
tion safety valve (8A) and then flows to
motor outlet port (MB) via motor inlet port
(MA). The motor outlet side is closed by
suction safety valve (8B) and spool (19),
so the pressure at the supply side rises.

● The pressurized oil on the supply side

flows to chamber (S1) via orifice (E1) and Travel control valve
orifice (E2) of the spool (19). As the pres- PA PB
sure in chamber (S1) goes above the spool
selector pressure, spool (19) is pushed
toward the right. Port (MB) and port (PB)
are connected, the motor outlet port side
opens and the motor starts rotating.
S1
19
MA MB
.
E1 E2
De al
ZX215-1002103
pt
Operation of brake during downhill travel
g n
● If the machine goes out of control while
o
travelling downhill, the motor will be caused Travel control valve
to rotate without load to decrease the inlet
in ti
PA PB
side oil pressure. Pressure in chamber (S1) 20
is released via orifices (E1) and (E2). As
the pressure in chamber (S1) goes below
et a
the spool selector pressure, spool (19)

n
is returned to the left by spring (20) and

S1
outlet port (MB) is throttled. The pressure
rk er
at the outlet port side rises, generating ro-

tation resistance on the motor to prevent
19
the machine from losing control. On the
Ma t
other hand, the spool moves to a position MA MB

In
where the pressure on outlet port (MB) can E1 E2

be balanced against the machine's own ZX215-1002104
weight and the inlet port pressure. Oil flow

from the outlet circuit is reduced to ensure
the travel speed corresponded to the pump
delivery.

2) Safety valve
Function
● When the machine travel is stopped (or it

is travelling downhill), the counterbalance
valve closes the inlet and outlet circuits of
the motor. Since the motor is rotated by
inertial force, pressure in the motor outlet
port side is abnormally increased, poten-
tially resulting in damages on the motor
and piping. The safety valve releases this
abnormal pressure to the inlet port side of
the motor in order to prevent damages to
.
the equipment.
De al
pt
Operation
g n Travel control valve
1. When travel is stopped (or when travelling
o
PA PB
downhill) (Right swing) 20
in ti
● Reduction of the pressure at motor inlet

(PA) decreases the pressure in chamber
et a
(S1). When it drops beyond the spool

switching pressure, the spool is returned to S1
n
the left by spring (20), reducing the pres-

sure at outlet passage (B1). At this time,
rk er
the motor continues rotating due to its iner-

tial force, thus pressure on the outlet port MA MB
(MB) is increased.
Ma t
A1 B1
In
ZX215-1002105
● When the pressure rises above the set

pressure of the suction safety valve (8A),
the poppet opens. The pressurized oil
passes through notch (A1) of spool (19)
into chamber (MA) of the circuit at the op-
posite side.
Spool MB MA
ZX215-1002107

2. When starting travel (or when traveling at a

constant speed) Travel control valve
PA PB 8B
● As the travel lever is operated, the pres-
surized oil from the pump moves spool (19)
toward right. The passage to the suction 8A
safety valve functions as a circuit which

passes through notch (B2) of spool (19),
producing large differential pressure. The S1
pump pressure rises, providing a large
tractional force to the valve.
19
MA MB
.
E1 B2
De al
ZX215-1002106
pt
3) Relief valve
g n
● The structure of the relief valve is shown
o
in the right figure. This valve is area dif-
in ti
ference and direct flow type. It has impact

damping function during starting and brak-
ing.
et a
n
rk er
ZX215-1002108
Ma t
A. Operation principle and function

In
● When the main valve makes the motor

to start or brake, front pressure of cone
valve (2-9-2) rises above the set pressure 2-9-2 2-9-5
and the force of spring (2-9-5), and moves
cone valve (2-9-2) to the right and off the
valve seat. Pressurized oil in the front of
cone valve (2-9-2) is bypassed to the low
pressure side. The impact due to inertia
energy at the high pressure side is put un-
der control and vacuum is prevented from 2-9-3
occurring at the low pressure side through
ZX215-1002109
bypassing pressurized oil to the low pres-
sure side.

B. Damping function
● When the relief valve begins to function,

damping piston (2-9-9) moves to the left. 2-9-2 Area S2 2-9-5
As a result, low pressure is maintained in
spring chamber D. At this time, the loaded
area of cone valve (2-9-2) is S1, and it is
much larger than the normal set loaded
area S1-S2 of the relief valve. So, when
damping piston (2-9-9) is moving, the func-
tional pressure of relief valve is maintained 2-9-3 Area S1 2-9-9 Spring chamber D
at 1/3 of normal set pressure in order to
ZX215-1002110
absorb the impact at the high pressure
circuit side due to inertia energy. When
.
De al
the movement of damping piston stops,
pt
pressure in spring chamber D rises. Pres-
sure at both side of cone valve (2-9-2) is
g n
the same, and the relief valve is working at
normal set pressure. In this way, the relief
o
valve reduces the impact during motor start
in ti
and brake by a two-stage action to provide

excellent performance.
et a
n
Pressure
rk er
Ma t
In
Damping method Time

ZX215-1002111

4.6.7 Valve control system
.
De al
pt
g n 7
6
o
1 2
4
in ti
10
3 5
5 9
6 7
et a
11 12
n
8 10
rk er
13
4
3
Ma t
2
In
11
1 12
ZX215-1002112

Control lever position
1. Travel PPC valve (1) HOLD

2. L. travel control lever (2) Boom UP
3. R. travel control lever (3) Boom DOWN
4. Right PPC valve (4) Bucket DUMP
5. Right joystick (5) Bucket DIG
6. Accumulator (6) HOLD
7. Transition block (7) Arm IN
8. Hydraulic pump (8) Arm OUT
9. Main control valve (9) Right swing
10. Solenoid valve (10) Left swing
.
De al
11. Left joystick (11) Neutral
pt
12. Left PPC valve (12) Reverse travel
(13) Forward travel
g no
in ti
et a
n
rk er
Ma t
In

4.6.8 Pilot valve
4.6.8.1 Work equipment and swing pilot valve
P3
P2
A
T
P
2
3
P
1
4
.
De al
pt
g n P1
P4
A
o
in ti
64~73.5N·m 19~22N·m
et a
n
rk er
Ma t
In
ZX215-1002113
P: From pilot pump relief valve

P1: L.H. Pilot valve: Arm OUT R.H. Pilot valve: Boom DOWN
P2: L.H. Pilot valve: Arm IN R.H. Pilot valve: Boom UP
P3: L.H. Pilot valve: Swing LEFT R.H Pilot valve: Bucket DIG
P4: L.H. Pilot valve: Swing RIGHT R.H. Pilot valve: Bucket DUMP
T: To tank

6
7
.
De al
pt
g n
4
o
9
in ti
3
et a
10
n
2
rk er
Ma t
1
In
A-A ZX215-1002114
(1) Plunger (6) Nut (for lever connection)

(2) Metering spring (7) Joint
(3) Centering spring (8) Plate
(4) Piston (9) Retainer
(5) Disc (10) Valve body

Operation
1. When in neutral
● Ports (A) and (B) of the control valve and

ports (P1) and (P2) of the pilot valve are
connected to drain chamber (D) via orifice D
(f) in plunger (1).
f
2. Fine control (Neutral to fine control) 1 T
● When piston (4) is pushed by disc (5),

retainer (9) is pushed, plunger (1) is also P
pushed by metering spring (2), and moves
.
De al
down.
pt
Pilot
● When orifice (f) is shut off from drain cham-
g n pump P1 P2
ber (D), it is almost simultaneously inter-
connected to pump pressure chamber (PP).
o
Pilot pressurized oil of the control pump is
A M M B
in ti
led to port (A) from port (P1) via orifice (f). Control valve
When the pressure at port (P1) becomes ZX215-1002115
higher, plunger (1) is pushed back and
et a
orifice (f) is shut off from pump pressure

chamber (PP). At almost the same time, it
n
is connected to drain chamber (D) to re-

lease the pressure at port (P1). As a result,
rk er
plunger (1) moves up and down until the

force of metering spring (2) is balanced
with the pressure at port (P1).
Ma t
D
In
● The relationship of the position of plunger

(1) and body (10) [orifice (f) is in the middle f
between drain chamber (D) and pump
pressure chamber (PP)] does not change 1 T
until retainer (9) contacts plunger (1). Me-
tering spring (2) contracts in proportion to P
the stroke of the control lever. Pressure
at port (P1) also rises in proportion to the
stroke of the control lever. In this way, the
control valve spool moves to a position Pilot
pump P1 P2
where the pressure of chamber (A) (same
as pressure at port (P1)) and the force of
the return spring of the control valve spool
are balanced.
A M Control valve M B
ZX215-1002116

3. During fine control (When control lever

is returned)
● When disc (5) starts to return, plunger

(1) is pushed up by the force of centering
spring (3) and the pressure at port (P1). D
● Because of this, orifice (f) is connected to f

drain chamber (D), and the pressurized oil
at port (P1) is released. 1 T
● If the pressure of port (P1) is lowered ex- P

cessively, plunger (1) is pushed down by
metering spring (2).
.
De al
f1
● Orifice (f) is shut off from drain chamber
pt
Pilot
(D), and it is almost simultaneously in- pump P1 P2
PP
terconnected to pump pressure chamber
g n
(PP). Pump pressure is supplied until the
o
pressure at port (P1) recovers to the level
A M M B
equivalent to the lever position. Control valve
in ti
ZX215-1002117
● When the spool of the control valve re-
turns, the oil in drain chamber (D) flows in
et a
from orifice (f) in the valve on the side that

n
is not working. The oil passes through port

(P2) and enters chamber (B) to replenish
rk er
the chamber with pressurized oil.
D
4. At full stroke
Ma t
f
In
● Disc (5) pushes down piston (4), and re-

tainer (9) pushes down plunger (1).
1 T
● Orifice (f) is shut off from drain chamber (D),
and is interconnected to pump pressure P
chamber (PP).
● Therefore, the pilot pressure oil from f1

the self pressure reducing valve passes Pilot
pump P1 P2
through orifice (f) and flows to chamber PP
(A) from port (P1) to push the control valve
spool.
A M M B
● The oil returning from chamber (B) passes Control valve
from port (P2) through orifice (f) and flows ZX215-1002118

to drain chamber (D).

4.6.8.2 Travel PPC valve
.
De al
pt
P
g n P
o
P5 A
in ti
P6
P5
P2 P1
et a
n
rk er
2 1
Ma t
4 3
In
P4 P3
ZX215-1002119
P: From pilot pump P4: R.H. forward

P1: L.H. reverse P5: Travel signal
P2: L.H. forward P6: Travel signal
P3: R.H. reverse T: To tank

37~30N·m
B
65~45N·m
1 8~6N·m
.
De al
pt
4
5
g no
6
C C
in ti
7
B-B
2，4 1，3
B
et a
13~11N·m
n
rk er
Ma t
In
C-C
8~6N·m
ZX215-1002120
(1) Plate (5) Centering spring

(2) Body (6) Metering spring
(3) Piston (7) Valve
(4) Collar

Operation
1. When in neutral
● Ports (A) and (B) of the control valve and

ports (P1) and (P2) of the Pilot valve are
D
connected to drain chamber (D) via orifice
(f) in plunger (1).
f
T
2. Fine control (Neutral to fine control) P
● When piston (4) is pushed by lever (5),

1
retainer (9) is pushed, plunger (1) is also
Pilot pump
pushed by metering spring (2), and moves P1 P2
.
down. When orifice (f) is shut off from drain
De al
chamber (D), it is almost simultaneously
pt
A B
interconnected to pump pressure chamber Control valve
(PP).
g n ZX215-1002121
● Pilot pressurized oil of the control pump is

o
led to port (A) from port (P1) via orifice (f).
in ti
● When the pressure at port (P1) becomes

higher, plunger (1) is pushed back and
orifice (f) is shut off from pump pressure
et a
5
chamber (PP). At almost the same time, it
4
n
is connected to drain chamber (D) to re-

lease the pressure at port (P1).
rk er
9 D
● As a result, plunger (1) moves up and 2
down until the force of metering spring (2) f
T
Ma t
is balanced with the pressure at port (P1). P

In
● The relationship of the position of plunger

1
(1) and body (10) [orifice (f) is in the middle
Pilot pump PP
between drain chamber (D) and pump P1 P2
pressure chamber (PP)] does not change 10
until retainer (9) contacts plunger (1). A B
Control valve
● Metering spring (2) contracts in proportion ZX215-1002122
to the stroke of the control lever.
● Pressure at port (P1) also rises in propor-

tion to the stroke of the control lever.
● In this way, the control valve spool moves

to a position where the pressure of cham-
ber (A) (same as pressure at port (P1)) and
the force of the return spring of the control
valve spool are balanced.

3. Fine control (When control lever is

returned)
● When lever (5) starts to return, plunger

(1) is pushed up by the force of centering 5
spring (3) and pressure at port (P1).
● Because of this, orifice (f) is connected to 3 D

drain chamber (D), and the pressurized oil 2
at port (P1) is released.
f T
● If the pressure of port (P1) is lowered ex- P
cessively, plunger (1) is pushed down by f’
metering spring (2). 1
.
De al
Pilot pump PP
● Orifice (f) is shut off from drain chamber (D), P1 P2
pt
and it is almost simultaneously intercon-
nected to pump pressure chamber (PP). A B
g n Control valve
ZX215-1002123
o
● Pump pressure is supplied until the pres-
sure at port (P1) recovers to the level
in ti
equivalent to the lever position.
● When the spool of the control valve re-

et a
turns, the oil in drain chamber (D) flows in

from orifice (f) in the valve on the side that
n
5
is not working. The oil passes through port 4
rk er
(P2) and enters chamber (B) to replenish

9 D
the chamber with pressurized oil.
Ma t
4. At full stroke f
T
In
P
● Lever (5) pushes down piston (4), and re- f’
tainer (9) pushes down plunger (1).
1
Pilot pump PP
● Orifice (f) is shut off from drain chamber (D), P1 P2
and is interconnected to pump pressure
chamber (PP). A Control valve B
● Therefore, the pilot pressure oil from ZX215-1002124
the self pressure reducing valve passes

through orifice (f) and flows to chamber
(A) from port (P1) to push the control valve
spool.
● The oil returning from chamber (B) passes

from port (P2) through orifice (f) and flows
to drain chamber (D).

4.6.9 Solenoid valve
Pilot valve lock, travel speed, bucket confluence, swing priority
1 2 3 4 5
.
De al
A6 A4 A3 A2 A1 P1
pt
g no
in ti
et a
WX13060401
n
(1) Travel hi/lo speed solenoid valve T: To oil tank

rk er
(2) Swing priority solenoid valve P: From accumulator and pilot pump
(3) Bucket confluence solenoid valve A1 To center swivel joint port
Ma t
(4) Boom to arm priority solenoid valve A2 To main valve port PsP
In
(5) Pilot lockout solenoid valve A3 To main valve port Xbp2

A4 To main valve port PnA2
A6 To pilot valve block P
NOTE: For the location of the solenoid valve on the machine, see “Hydraulic equipment layout”
on page 4-24.

4.6.10 Accumulator
.
4
De al
pt
5
g no
in ti
6
ZX215-1002126
et a
(1) Gas plug Specifications

n
(2) Shell
Gas capacity: 300 cm³
(3) Poppet
rk er
(4) Holder
(5) Bladder
Ma t
(6) Oil port

In

4.6.11 Pilot oil filter
1
K
2
型号
压力
精度
3
.
De al
pt
g no
5
in ti
6
et a
n
rk er
3
Ma t
ZX215-1002127
In
Specifications
(1) Name plate Max. delivery: 40 L/min

(2) Head cover Filter fineness: 10 μm
(3) O-ring Operating pressure: 20 Mpa
(4) Seal Max. operating pressure: 40 Mpa
(5) Filter Pressure loss: 0.05 Mpa
(6) Case Max. allowable pressure difference: 1 Mpa
Specification of inlet/outlet port o-ring: 30×3.1

4.6.12 Pump oil pressure sensor
1 2 3
A B
4
ZX215-1002128
.
De al
(1) Pressure connector
pt
(2) Name plate g n
(3) Connector
o
(4) Vent hole
in ti
Function
● This sensor measures pump oil pressure

et a
and uses it to control various machine op-

n
erations. When oil pressure compresses

the diaphragm, it deforms and this is de-
rk er
tected in the form of electric signals.

Ma t
In

4.6.13 Hydraulic cylinder
Boom cylinder
5340±50N.m
2 1 544.9±5.1kgm 3
56.9±10.7N.m
267±35N.m 5.8±1.1kgm
27.2±3.6kgm
.
ZX215-1002129
De al
pt
Arm cylinder g n
7900±50N.m
o
2 1 806.1±5.1kgm 3
in ti
et a
n
56.9±10.7N.m
367±35N.m
5.8±1.1kgm
rk er
37.4±3.6kgm
ZX215-1002130
Ma t
Bucket cylinder
In
5480±50N.m
2 1 559.2±5.1kgm
3
56.9±10.7N.m
267±35N.m
5.8±1.1kgm
27.2±3.6kgm
ZX215-1002131

100 hours greasing
Unit: mm
Cylinder
size Shaft Hole clearance limit
-0.036 +0.222
Clearance between pis- Boom 85 0.083 – 0.312 0.412 Replace
1 -0.090 +0.047
ton rod and bushing -0.036 +0.222 bushing
Arm 95 0.083 – 0.312 0.412
-0.090 +0.047
-0.030 +0.258
Bucket 80 0.078 – 0.334 0.434
-0.076 +0.048
-0.030 +0.246
Boom 80 0.230 – 0.322 1.0
.
-0.076 +0.200
De al
Clearance between pis-
-0.030 +0.246
pt
2 ton rod support pin and Arm 80 0.230 – 0.322 1.0
-0.076 +0.200
bushing -0.030 +0.246
Bucket 70 0.230 – 0.322 1.0 Replace
g n -0.076 +0.200
pin or
-0.030 +0.246
o
Boom 70 0.230 – 0.322 1.0 bushing
Clearance between cyl- -0.076 +0.200
in ti
-0.030 +0.246
3 inder bottom support pin Arm 80 0.230 – 0.322 1.0
-0.076 +0.200
and bushing -0.030 +0.246
Bucket 70 0.230 – 0.322 1.0
-0.076 +0.200
et a
n
500 hours greasing

Unit: mm
rk er

Cylinder
Ma t
size Shaft Hole clearance limit

In
-0.036 +0.222
Clearance between pis- Boom 85 0.083 – 0.312 0.412 Replace
1 -0.090 +0.047
ton rod and bushing -0.036 +0.222 bushing
Arm 95 0.083 – 0.312 0.412
-0.090 +0.047
-0.030 +0.258
Bucket 80 0.078 – 0.334 0.434
-0.076 +0.048
-0.030 +0.246
Boom 80 0.230 – 0.322 1.0
Clearance between pis- -0.076 +0.200
-0.030 +0.246
2 ton rod support pin and Arm 80 0.230 – 0.322 1.0
-0.076 +0.200
bushing -0.030 +0.246
Bucket 70 0.230 – 0.322 1.0 Replace
-0.076 +0.200
pin or
-0.030 +0.246
Boom 70 0.230 – 0.322 1.0 bushing
Clearance between cyl- -0.076 +0.200
-0.030 +0.246
3 inder bottom support pin Arm 80 0.230 – 0.322 1.0
-0.076 +0.200
and bushing -0.030 +0.246
Bucket 70 0.230 – 0.322 1.0
-0.076 +0.200

4.6.14 Work equipment
F
D
G E
.
De al
J
pt
g no
,
A
in ti
K H B
et a
ZX215-1002133
n
rk er
1
6
Ma t
In
3 ,-,
A-A
C-C
5
B-B
2 4 J-J
G-G
H-H
E-E D-D F-F K-K

ZX215-1002134

100 hour greasing
Unit: mm
Standard Tolerance Standard clear- Clearance

Clearance between pin connect-
size Shaft Hole ance limit
1 ing boom and revolving frame and
–0.036 +0.140
bushing 90 0.141 ~ 0.211 1.0
–0.071 +0.105
Clearance between pin connecting –0.036 +0.174
2 90 0.140 ~ 0.345 1.0
boom and arm and bushing –0.071 +0.104
3 70 0.305 ~ 0.395 1.0 Replace
arm and rocker and bushing –0.060 +0.275
.
De al
pt
4 80 0.300 ~ 0.384 1.0
arm and bucket and bushing –0.060 +0.270
5
g n
linkage and bucket and bushing
o
80
–0.060 +0.273
0.303 ~ 0.433 1.0

6 70 0.305 ~ 0.395 1.0
linkages and bushing –0.060 +0.275
in ti
et a
500 hour greasing

n
Unit: mm
rk er
Standard Tolerance Standard clear- Clearance

Clearance between pin connect-
Ma t
size Shaft Hole ance limit

1 ing boom and revolving frame and
–0.036 +0.131
In
bushing 90 0.110 ~ 0.202 1.0

–0.071 +0.074
2 90 0.110 ~ 0.237 1.0
boom and arm and bushing –0.071 +0.074
3 70 0.108 ~ 0.218 1.0 Replace
arm and rocker and bushing –0.060 +0.078
4 80 0.104 ~ 0.197 1.0
arm and bucket and bushing –0.060 +0.074
5 80 0.116 ~ 0.226 1.0
linkage and bucket and bushing –0.060 +0.086
6 70 0.104 ~ 0.214 1.0
linkages and bushing –0.060 +0.074

Arm dimension
11
B 19
12 5
A C D
A
D 6
.
De al
B 14 C
10
pt
g n 8 7
13
o
in ti
A-A B-B
et a
15
n
rk er
18 16
Ma t
In
17
C-C D-D
4
3
2
WX13060402

Unit: mm
SY195/205/215C-9 SY225C-9
No.
Standard size Tolerance Standard size Tolerance
+0.1 +0.1
1 φ80 φ80
0 0
±0.5 ±0.5
2 107 107
0 0
-0.3 -0.3
3 310 310
-0.8 -0.8
-0.036 -0.036
4 φ90 φ90
-0.071 -0.071
5 549 ±1 549 ±1
.
De al
6 158 ±0.8 158 ±0.8
pt
7 835 ±1 835 ±1
8 2,911 ±2 2,911 ±2
g n
9 2,643 ±2 2,643 ±2
o
10 411 ±0.8 411 ±0.8
in ti
0 0
11 640 640
-0.5 -0.5
12 600 — 600 —
et a
13 458 — 458 —
n
14 1,483 — 1,495 —
rk er
15 φ80 — φ80 —
16 326.5 — 326.5 —
+0.2 +0.2
Ma t
17 φ80 φ80
0 0
In
Arm itself 311 — 311 —

18 When press fit-
325 — 325 —
ting bushing
Min. 1,680 — 1,680 —
19
Max. 2,800 — 2,800 —

Bucket dimension
2 5
A
18 17
6
1 4
16
.
De al
pt
19
g n
7
o
in ti
A
12
et a
11 9 10
n
13
rk er 15
14
8
Ma t
In
15
8
20 21 22
A-A WX13060403

Unit: mm
SY195/205/215C-9 SY225C-9
No.
Standard size Tolerance Standard size Tolerance
1 457.5 ±0.5 457.5 ±0.5
2 22 ±0.5 22 ±0.5
3 91.8° — 91.8° —
4 458 — 458 —
5 1,483 — 1,483 —
6 177 — 177 —
7 45° — 45° —
+0.2 +0.2
8 φ80 φ80
.
0 0
De al
+0.2 +0.2
pt
9 348.5 348.5
0 0
10 37 — 37 —
11 107
g no
— 107 —
12 473.5 — 473.5 —
in ti
13 φ23.5 — φ23.5 —
14 φ190 — φ190 —
15 φ136 — φ136 —
et a
16 131 — 131 —
n
17 125 — 125 —
rk er
18 R180 — R180 —
19 R140 — R140 —
20 57 — 57 —
Ma t
21 326.5 ±0.5 326.5 ±0.5

In

4.7 Air Conditioning System
1
2
.
De al
pt
g n C
C
o
C
in ti
A
et a
n
C B
rk er
6
C
Ma t
7
In
8
ZX215-1002137
(1) Hot water piping A. Fresh air

(2) A/C compressor (DENSO.2)
B. Recirculated air
(3) Refrigeration piping
(4) Condenser (SG447750-A040) C. Warm air/cool air
(5) Receiver tank (DENSO.4)

(6) Hot water return piping
(7) A/C unit assembly (SG443180-9320)
(8) Air duct

4.7.1 A/C components layout drawing
2
1
3
4
.
De al
pt
g n 5
o
in ti
et a
n
rk er
7 6
Ma t
In
ZX215-1002138
(1) Sunlight sensor (5) Compressor

(2) Control panel (6) Fresh air sensor
(3) Air conditioning unit (7) Recirculated air sensor
(4) Condenser

4.7.2 Control panel
1 2 3 4 5
.
De al
6 7 8
pt
CZ205-1203020G
(1) OFF switch (5) Auto mode switch

g n
(2) Fan speed control switch (6) Air circulation control switch
o
(3) Temperature control switch (7) LCD display
in ti
(4) Air outlet mode switch (8) A/C switch

et a
n
rk er
Ma t
In

SY195/205/215/225C9 Crawler Hydraulic Excavator
.
pt SW Wiring diagram
1.25R
7
FURM B G1 G2 ACC M ST
3
FL1
3 8
H
FUCD 20A FUM OFF
2
2
60A
CMB
De al 15A
RLCD
8
RLCC
8
8
1.25R
RLBM
13
5A
13
ACC
ON
START
15 13
MRF
M
RLCC RLCD RLBM
g n
Shop Manual - November 2014

9 10
GND
REC
FFE
1
Vz
2RL 1.25RL
Pt
10 1.25L 15
1
o D MR
16 16 19 25 24 22 26 25
RLSF 5 2
5
5
FLZ
40A
SW
in ti M
MCD
80W
SPCD
11
1.256
M
10
10
4
2G
200W
10 BLCM
3
13
6
+B 16
16
19
19
25
22
24
23
26
1
1
BAT
ACC 7
6
et a
n
BLC
1
2
RLCH
12 12
8
28 15 14 12 13 3 16 27 4 21
ACM
20 2 24 25 9 38 26 10
rk er
7 G 12 14 17 18 20 22 21 15 23 27 28 29 30 31 32 32 34 35
D1 9
RCD RLCH RLCH ECC THAM THW THI THF SSD
40W
G 4 22
02 02 02 15 15 15
03 15
4 4
CMB
Ma t
D2 30 31 22 32 15 33 34 35 35 22
1.25B
1.25B
3
SPHL
CM
Structure and Function
0.85B
0.50
02 02
M M M
2B
4.7.3 Circuit diagram
0.5B
In
06
2B 2B
01 02
06
03
MAM MV1 MV2
4-132
Wire No. Diameter/Color code Wire color Wire No. Diameter/Color code Wire color
B Black 0.5VW Violet+white
Br(R) Brown 0.5YB Yellow+black
0.85W White 0.5WO White+orange
RL Red+blue 0.5PB Pink+black
G Green 0.5VR Violet+red
0.5BL Black+blue 0.5BG Black+green
0.5R Red+blue 0.5WY White+yellow
0.5Y Yellow 0.5WR White+red
0.5BR Black+red 0.5BrW Brown+white
0.5BrY Brown+yellow 0.5GO Green+orange
.
De al
0.5BY Black+yellow 0.5Sb Sky blue
pt
0.5GW
g n Green+white 0.5OW Orange+white
0.5LO Blue+orange 1.25V Violet
0.5PG Pink+green 1.25RG Red+green
o
0.5RY Red+yellow 1.25RW Red+orange
in ti
0.5BW Black+white 0.85GL Green+Blue

0.5LgR Light green+red
et a
n
Code Name Code Name Code Name

rk er
Condenser high speed

ACM A/C amplifier FUCD Condenser fuse RLCH
relay
BAT Battery FUM A/C main fuse RLSF Protective relay
Ma t
BLC Speed regulating resistor G Alternator SSD Sunlight sensor

In
Condenser pressure
CMB Battery relay MAM A/M servo motor SPCD
switch
D Diode MB Blower motor SPHL HI/LO pressure switch
D1 Diode 1 MCD Condenser motor SW Switcher
Internal/External air servo
D2 Diode 2 MRF THAM External air thermistor
motor
ECC Compressor clutch MV1 Air outlet servo motor THF Anti-frosting thermistor
FL1 Fuse MV2 FRONT outlet servo motor THI Internal air thermistor
FL2 Fuse RCD Condenser resistor THW Water temp. thermistor
FUBM Blower fuse RLBM Blower main relay
RLCC Compressor relay RLCD Condenser relay

4.7.4 Refrigeration principle
4.7.4.1 Refrigeration cycle diagram
Cool air Expansion valve
Lo temp\Lo press liquid (Mist)

Evaporator
Lo temp\Lo press gas
Hi temp\Hi press liquid

Cooling fan
Blower
.
Air in cab
De al
Out side fresh air
pt
Hi-temp hi-pres gas
Receiver
g n
Condenser
o
Lo-pres. Hi-pres.
side side
in ti
Compressor
et a
Hot air
n
Lo-pressure portion Hi-pressure portion

ZX215-1002141
rk er
4.7.4.2 Heating cycle diagram

Ma t
Radiator Water valve control

In
Water pump Hot air
Engine
Blower motor
Internal air
Low tempr water

High temp water ZX215-1002142

4.7.5 Compressor
3 4
1 2
16
15
.
De al
14
pt
g no
5
13
in ti
et a
6
n
rk er
12
11 10 9 8 7
ZX215-1002143
Ma t
In
(1) Stator (9) Slipper

(2) Front radial bearing (10) Front cylinder block
(3) Thrust bearing (11) Piston
(4) Front radial bearing (12) Front cylinder head
(5) Rear cylinder head (13) Shaft seal
(6) Safety valve (14) Main shaft
(7) Rear cylinder block (15) Hub
(8) Swash plate (16) Rotor

Operating principle
Compressor type: 10S15C. This compres- back and forth and transforms the refrigerant
sor has 5 plungers in total with a piston on sucked from the evaporator from low tempera-
both sides of each plunger. The rotation of ture and low pressure gas state to high tem-
the swash plate drives the pistons to move perature and high pressure state.
Process1 Process2
HI press.end pipe LO press.end pipe HI press.end pipe LO press.end pipe
Valve plate
Outlet valve disc
.
De al
pt
g n
Main shaft and swash plate Intlet valve disc
o
in ti
Process6 Process3

et a
n
rk er
Ma t
In
Process5 Process4
ZX215-1002144

4.7.6 Clutch
(1) Rotor
1
(2) Stator coil
2
(3) Snap ring
3
(4) Ball bearing 4
(5) Stator
(6) Center piece
● The electromagnetic clutch is used to
.
transmit moment of torsion. When the en-
De al
6
gine is operating, the compressor may not
pt
ZX215-1002145
be working. The clutch controls the opera-
tion of the compressor only when the air
g n
conditioner is under refrigerating mode.
o
● Operating principle
in ti
When the A/C switch is turned on, the

clutch coil with an electromagnet gener-
et a
ates a magnetic field and attracts the metal

piece. The stator and rotor of the clutch are
n
engaged and drives the main shaft of the

rk er
compressor into rotation.

Ma t
In

4.7.8 Condenser
1
4
2
.
De al
pt
g n 5
o
ZX215-1002146
in ti
(1) Condenser core (4) Refrigerant inlet

(2) Bracket (5) Refrigerant outlet
et a
(3) Bolt with gasket

n
Function
rk er
● The condenser converts high-temperature,

high-pressure gas refrigerant (16Kg/cm²,
about 80°C) to high-temperature and high-
Ma t
pressure liquid refrigerant (16Kg/cm², be-

In
low 60°C) through radiating.
4.7.7 Expansion valve

Evaporator
2
(1) Spring
(2) Diaphragm 1
(3) Probe
(4) Needle valve
Operating principle
3
● Refrigerant from the receiver tank spurts
out via the orifice, turns into low-temper- 4 Compressor
ature, low-pressure liquid (mist) after ex- Reservoir
ZX215-1002147
panding, and enters the evaporator.

4.7.9 Evaporator
(1) Expansion valve

(2) Evaporator
Operating principle
● The evaporator is a kind of heat exchanger

that looks like a condenser. Hot air in the
cab is conducted into the evaporator via
the blower motor and undergoes heat ex-
change with the surface of the evaporator. 2
1
Heat is absorbed and hot air turns into
cold air, which flows into the cab through
.
De al
the air ducts. Evaporator surface absorbs ZX215-1002148
pt
heat→Refrigerant in the evaporator ab-
sorbs heat → Refrigerant evaporates .
g n
Evaporated refrigerant (gas) is absorbed
by the compressor.
o
in ti
4.7.10 Receiver tank

et a
(1) Inlet 2
n
1
(2) Outlet
rk er
(3) Receiver/dehydrator
(4) Desiccant
Ma t
In
Function
3
● Temporary storage of refrigerant
● Dehydration of refrigerant
4
● Dust removal from refrigerant
● Measure the volume of refrigerant
ZX215-1002149

4.7.11 Pressure switch
(1) O-ring
Pressure
(2) Mobile contact point
(3) Hood
1
(4) Plug and fixed contact 7
(5) Spring 2
6
(6) Chamber
(7) Diaphragm
Function
.
3
De al
5
● The pressure switch is installed between
pt
the receiver tank and the expansion
valve (hi-pressure pipe). It is a combina-
g n 4
tion switch (Hi-Lo pressure combination
o
switch).
ZX215-1002150
in ti
● When pressure is excessively high, the

compressor stops.
et a
● When pressure and temperature is very

low, the compressor stops.
n
rk er
Operating features
Ma t
In
Feature
DIFF DIFF
HI pressure ON
operating value Above 0.02 MPa 0.59±0.2 MPa
OFF
LO pressure 0.196±0.02 MPa 0.196~0.250 MPa 2.94~3.19 MPa
operating value
ON
MID pressure
operating value OFF
1.23±0.1 MPa 1.52±0.08 MPa

4.7.12 Fresh air sensor
The fresh air sensor is installed beside the

condenser or around the fresh air inlet. It mea-
sures the temperature of outside air and it is
12
composed of thermistors.
/K¡
10
Technical specifications
Resistance value
8
Item Specification
6
Service voltage range 4.4~5.6 V
4
Service temp range -30~60 °C
Storage temp range -40~90 °C 2
.
De al
Resistance value 1700±85Ω
pt
-10 0 10 20 30 40 AT
B constant 3900±195 K ZX215-1002151
Allowable operating current 1.6 mA (MAX)
g no
in ti
4.7.13 Refrigerant
et a
WARNING
n
● Obey local material disposal regula-

tions. Never discharge refrigerant di-
rk er
rectly into the air.
● Refrigerant R134 a is a harmless gas

Ma t
under room temperature. It will change

In
into highly toxic gas when burning.
● Refrigerant getting into eyes may cause

blindness. It may cause frostbite if
splashed on your skin.
1. General property
● High heat absorption and easy liquefaction

● Non-flammable, nonexplosive
● Stable chemical composition
● Non-toxic
● Non-corrosive
● No hazard to clothing

2. Refrigerant cycle
● After evaporation in the evaporator, refrigerant turns from gas into liquid via the compressor
and the condenser, which finishes a refrigerant cycle.
Compressor LO press. side (inlet): LO temp?LO press.?Gas

Compressor Pressure/Temperature:2Kg/cm²，approx. 8ć
Evaporator
IntakeėDischarge Absorb heatėEmit cold air
Compress HI press. side(outlet): HI temp\HI press.\Gas

Pressure/Temperature:16Kg/cm²ˈapprox. 80ć
.
Condensor (outlet): LO temp\LO press.\Mist
De al
Pressure/Temperature: 2Kg/cm²ˈapprox. 0~2ć
pt
g n
Condensor (outlet)˖HI temp?HI pressure?Liquid Expansion valve
o
Condensor Pressure/Tempterature˖16Kg/cm²ˈBelow 60ć
Hi pressureėLo pressure
Via radiating:Gas refri-
in ti
Hi tempėLo temp
gerantėLiquid refrigerant
LiquidėMist
● Refrigerant cycle principle (pressure - enthalpy diagram)

et a
n
lgp
rk er
Liquefaction completed Refrigerant cyclic curve
Liquefaction starts
Ma t
Throttling point Condensor

In
Condensing process
Liquid
Expansion throttle
Compressing
Expansion valve process Compressor
Evaporating process
Evaporator
Gas-liquid mixture Gasification completed
h=u+Apv(kJ/kg)
UInternal energy pPressure VSpecial volume AJoule equivalent

3. Feeding of refrigerant
● Filling method and volume:
1) Refrigerant: HFC-134a
2) Feeding volume: 850±50 g (for reference)
3) Feeding method: Feeding of liquid refrig-

erant from the low-pressure end is not al-
lowed. If feeding operation fails, discharge
the refrigerant that has been fed before re-
feeding.
.
De al
pt
ZX215-1002153
g no
in ti
● Inspect the state of the refrigerant in the

A/C circulation system through the sight Sight glass
glass:
et a
1) Correct feeding: Foam is hardly observed

n
when the refrigerant is flowing. When en-

gine speed increases from idling to 1500
rk er
rpm, foam disappears and the refrigerant Proper filling

turns clear.
Ma t
2) Over-feeding: No foam can be observed

when refrigerant is flowing.
In
3) Under-feeding: Foam is always observed Inadequate filling

when refrigerant is flowing. ZX215-1002154

4. Evacuation
● No moisture shall exit in the air condition-

ing unit. Refrigerant (R134a) is soluble in
water. Very small amount of moisture in
the unit can cause the orifice of the expan-
sion valve to ice up, or cause the compres-
sor valve to rust. To avoid such problems,
moisture in the system shall be removed
before refrigerant is added. To minimize
the residual moisture in the system, mois-
ture in the system can evaporate through
evacuating.
.
De al
pt
Evacuating steps
Step 1: Connect the manifold pressure gauge

g n
1) Close the high-pressure valve (HI) and
o
Valve
low-pressure valve (LO) of the manifold LO HI
Lo-pres.gauge
LO HI
above 750mmHg
in ti
pressure gauge. Lo-pres. ON ON OFF OFF
gauge
Hi-pres. gauge
2) Connect the hoses (red, blue) to the auxil-
iary valve of the compressor.
et a
Hi-pres. valve(ON)
Lo-pres. valve (ON)
Red hose – High pressure side (Mark D)
n
Green
Red D
Blue hose – Low pressure side (Mark S)
rk er
Blue
NOTE: Connect the end of the hose with a S
L to the auxiliary valve of the compressor.

Ma t
If connected inversely, the valve will not Compressor

Vacuum pump (running)
open. Besides, do not inversely connect
In
ZX215-1002155
the high-pressure end and the low-
pressure end.
3) Connect the green hose to the vacuum

pump.

Step 2: Evacuation
1) Open the high-pressure valve (HI) and low-

pressure valve (LO) on the manifold pres-
sure gauge.
2) Turn on the vacuum pump and evacuate

for about 15 minutes.
3) When negative pressure reading on the

gauge (degree of vacuum) reaches above
750 mmHg, turn off the vacuum pump and
close the Hi-pressure valve and the Lo-
pressure valve on the gauge.
.
De al
pt
Step 3: Air - proof check
g n
1) Keep the Hi- and Lo-pressure valve of the
o
manifold pressure gauge under closed
in ti
state for more than 5 minutes, and make Valve

sure the pointer on the gauge does not re- Lo Hi Wait 5 min. or more Lo-press. gauge
OFF OFF returns to 0
turn to zero.
Lo-press. gauge
et a
2) If the pointer returns to near zero, a leak-

n
age is available somewhere. Check and

adjust the pipe joint. Tighten the joint and
rk er
Pointer returns
conduct another evacuating operation until to 0 Tighten pipe joint
no leakage is detected.
Ma t
ZX215-1002156
In

Step 4: Leak check
1) Connect the green hose that is previously Valve

connected to the vacuum pump to the Lo Hi
fluorine cylinder. OFF OFF
2) Connect the other end of the green hose

to the pressure gauge. Open the valve of
Vent valve
the cylinder and press the vent valve of the
Release air
pressure gauge. (Do not press the valve Open
with naked hand to avoid frostbite caused
by refrigerant). Release the air in the
hose with the pressure of the refrigerant. Blue
(Release the vent valve when you hear a Green

R134a
.
Red
squeezing sound).
De al
pt
To compressor Fluorine cylinder
ZX215-1002157
g no
3) Add refrigerant until pressure reading on
in ti
the Lo-pressure gauge is 1kgf/cm² . Hi-

Valve
pressure valve of the gauge is open at this Lo Hi Lo-press gauge Lo Hi
2
at 1kgf/cm
time. Close the Hi-pressure valve when OFF ON OFF OFF
et a
Lo-pres. gauge
feeding is finished. reads1kgf/cm2
n
4) Use a leak detector to check if leakage is

Lo-pres.valve (OFF)
rk er
Open Hi-pres.valve
available in the cooling system.
Cylinder valve (ON)
5) Make necessary repairs (tightening) if leak- D
age is observed.
Ma t
S
R134a
In
Compressor
Fluorine cylinder
ZX215-1002158

5. Refrigerant charging operation
● When evacuation is finished, add refrigerant into the cooling system as per the following in-
struction:
Add refrigerant kgf/cm2

Air-proofness check
Performance testing
Evacuation starts
Evacuation ends
Add refrigerant
Air leak check
Air leak check

75cm-Hg or more
More than 15 min. Wait 5 min. Pres. gauge

normal
Pres. gauge
Tighten pipe joint (1) Compressor stopped, charge at hi-press end
.
abnormal
De al
Check leak point (2)Compressor running, add at lo-press end
pt
Charge at the hi-pressure side g n Valve
Lo Hi
1. Remove the green hose of the manifold OFF OFF
o
pressure gauge from the vacuum pump
and connect it to the fluorine cylinder.
in ti
2. Loosen the cylinder valve and press the Vent valve
vent valve on the gauge. Use the pressure

et a
Open
of the refrigerant to release the air in the Loosen
this nut
n
hose.
Blue
rk er
NOTE: Release the vent valve when you

Green
hear a hissing sound. Red R134a
To compressor Fluorine cylinder

Ma t
ZX215-1002159
CAUTION
In
● Do not press the valve with naked hand

to avoid frostbite.
3. Open the hi-pressure valve of the manifold Valve

Lo Hi A cylinder Lo Hi
pressure gauge and the cylinder valve with OFF ON
(about 600g)
OFF OFF
the engine stopped. Fill about 600g of re-
frigerant. gDo not operate compressor
Lo-press. gDo not open Lo-pressure valve
4. Close the hi-pressure valve of the pressure valve (OFF) Open Hi-press. valve
gauge and shut the cylinder valve. Fluorine cylinder
valve (ON)
D
S
R134a
ZX215-1002160

CAUTION
● Do not operate the compressor when
refrigerant charging is in progress.
Otherwise, refrigerant will counterflow
and cause the cylinder and hoses to ex-
plode.
● Operating the compressor with no re-

frigerant in the system will cause dam-
age to the compressor.
● Do not open the lo-pressure valve of the

manifold pressure gauge; otherwise,
.
the compressor will be damaged.
De al
pt
Charge at the lo-pressure side (refill)
g n
1. Check that the hi-pressure valve of the
o
manifold pressure gauge is closed.
in ti
2. Start the engine.

Hi-press. valve (OFF) ON
Manifold pressure
3. Turn on the A/C unit. Adjust Temperature
et a
gauge
control switch to minimum.
H I
n
4. Adjust engine speed to 1300 – 1500 rpm.

rk er
Start the engine

5. Open the Lo-pressure valve of the mani- 1300~1500rpm
fold pressure gauge and the cylinder valve.
Add refrigerant until no foam is observed
Ma t
ZX215-1002161
through the sight glass.
In
Remark: Valve
When no foam
Lo Hi Lo Hi
Manifold pressure gauge reading (for refer- ON OFF
is observed
OFF OFF
Lo-press. gauge
ence): (1.5~2.5kgf/cm2) Hi-press. gauge
(13~17kgf/cm2)
HIGH pressure:
Lo-press. Hi-press. valve (OFF)
valve (ON) (Never open it)
13~17kgf/cm² (when ambient temperature Fluorine cylinder
is 30°C) valve (ON)
LOW pressure:
1.5~2kgf/cm² (when ambient temperature Compressor

Fluorine cylinder
is 30°C). (never placed upside down) running
ZX215-1002162

6. When refrigerant charging is finished,

close the Lo-pressure valve of the mani-
fold pressure gauge and the valve of the
fluorine cylinder.
7. Check carefully for air leaks with a leak

detector.
CAUTION
● Opening the Hi-pressure valve of the
pressure gauge will cause pressurized
gas to counterflow and cause the hoses
and the fluorine cylinder to explode, re-
.
sulting in serious damage.
De al
pt
● When engine is running and charging in
progress, placing the fluorine cylinder
g n
upside down will cause liquid refriger-
o
ant to be sucked directly into the com-
pressor and cause liquid compression,
in ti
resulting in equipment damage.

et a
8. When ambient temperature is low

n
Valve
When refrigerant charging gets difficult Lo Hi When no foam Lo Hi
due to low temperature, put the cylinder in ON OFF is seen OFF OFF
rk er
warm water (max. 40°C).
9. When ambient temperature is high Lo-pressure

Ma t
valve (ON) Hi-pressure valve

(OFF)
When ambient temperature is very high, Cylinder valve
In
(ON)
cool the compressor with an electrical fan.
Compressor
Water less than 40°C running
(Do not use hot water)
ZX215-1002163

Replace the fluorine cylinder
When the refrigerant in a cylinder is used up,

replace the cylinder as per the following in-
Handle
struction:
1. Close the Hi- and Lo-pressure valves of

the manifold pressure gauge.
Air hose connector
2. Raise the needle and disc plate of the cyl- Needle valve
inder and remove the empty cylinder.
3. Install a new cylinder onto the cylinder Gasket
valve. Disc plate

Refrigerant
.
4. Release the air in the hose as per the fol- cylinder
De al
lowing instruction:
pt
ZX215-1002164
1) Tighten the valve of the fluorine cylinder,
g n
and then, loosen it a bit.
o
2) Open the Lo-pressure valve of the mani-
fold pressure gauge a bit.
in ti
3) Press the vent valve and allow a little re-

frigerant to come out. Immediately close
et a
the valve of the cylinder and the Lo-

pressure valve of the manifold pressure
n
gauge.
rk er
CAUTION Valve
Lo Hi
Ma t
Loose OFF
● Do not press the valve with naked hand Close the Lo-pressure valve
In
to avoid frostbite. once you hear the hissing sound
5. Turn the handle of the cylinder valve to

pierce the cylinder and continue charging Loosen the valve a bit
Lo-pressure
operation. valve
Green
Blue
R-134a
Red
To compressor Refrigerant cylinder

ZX215-1002165

6. Fault testing with manifold pressure gauge
After the engine has been preheated, read the pressure value on the gauge under the following
conditions:
1) Temperature at air inlet: 30 – 35°C
2) Engine speed: 1500 rpm
3) Fan speed: High
4) Temperature control: Minimum.
5) Air circulation mode: Recirculation
.
● Cooling system under normal condition
De al
pt
Gauge reading:
Lo-pressure end: 0.15~0.25 Mpa (1.5~2.5 Kgf/cm²)

g n
Hi-pressure end: 1.37~1.57 Mpa (14~16 Kgf/cm²)
o
in ti
et a
04 15 2
03 05
4 15 20
3 5
1
n
02 06
2 6 10 25
25
7
1
01 07 5 30
rk er
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}

0 8 3
-50 8.5 0
0 08
-76 -76 35
085 0
-01 15 -01 35
MPa MPa
Ma t
R134a
In
ZX215-1002167

● Moisture in the refrigerating system
Symptom: Intermittent refrigeration to non-refrigeration
04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1
01 07 5 30
8 3
0
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01 35
MPa MPa
.
De al
ZX215-1002168
pt
Symptom
g n Cause Analysis Remedy
● When the system is ● Moisture in the system ● Over-saturation of de- ● Replace receiver/
o
operating, pressure ices up at the expan- hydrator. dehydrator
in ti
at the Lo-pressure sion valve causing
● Moisture in the system ● Remove the mois-
end unstable (some- circular temporary
ices up at the expan- ture in the system
times vacuum, stop. When ice melts,
sion valve and hinders through constant
et a
sometimes normal) the system becomes

the circulation of the pumping.
normal again.
n
refrigerating system.
● Add proper volume
rk er
of new refrigerant.
Ma t
In

● Insufficient refrigeration
Symptom: Insufficient refrigeration
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01 35
MPa MPa
.
De al
ZX215-1002169
pt
Symptom Cause Analysis Remedy
g n
● Pressure at both Hi- and
o
● Air leaks ● Insufficient ● Check for air leakage with a leak
Ho-pressure ends very somewhere refrigerant in the detector. Make necessary re-
low in the refrig- system pairs.
in ti
erating sys-
● Foam is continuously ob- ● Leak of refriger- ● Add proper amount of refriger-
tem
served via the sight glass ant ant.
et a
● Insufficient refrigeration. ● When connected with the gauge,

n
if the reading is near zero, set

the system under vacuum state
rk er
after inspection and repair.

Ma t
In

● Defective refrigerant circulation
Symptom: insufficient refrigeration
04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01 35
MPa MPa
.
De al
ZX215-1002170
pt
g n
● Pressure at both ● Contaminant in the ● Blocked reservoir ● Replace reservoir
o
Hi- and Lo-pressure reservoir hinders the
sides very low flow of refrigerant.
in ti
● Frosting on the pip-

ing between parts
et a
and reservoir
n
rk er
Ma t
In

● Refrigerant not circulating
Symptom: Non-refrigeration (intermittent refrigeration)
04 15 2
03 05
4 15 20
3 5
1
02 06 25
2 6 10 25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01 35
MPa MPa
.
ZX215-1002171
De al
pt
g n
● Vacuum at Lo-pres- ● Moisture or contami- ● Refrigerant not ● Check the expansion valve
o
sure side; pressure nant in the refrigerant circulating and ERP.
at Hi-pressure side hinders the flow of
in ti
● Blow the contaminant in the

extremely low refrigerant.
expansion valve or replace
● Frosting or conden- ● Air leak at the thermal the expansion valve if nec-
et a
sation on the pipes pipe of the expansion essary.

n
around the expan- valve hinders the flow

● Replace the receiver
sion valve or receiv- of refrigerant.
rk er
er/dehydrator ● Release internal air and

add refrigerant. If air leaks
from thermal pipe, replace
Ma t
expansion valve.
In

● Over-charging of refrigerant or insufficient refrigeration of condenser
Symptom: Insufficient refrigeration
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 35
-76 -76
085 0
-01 15 -01
35
MPa MPa
.
De al
ZX215-1002172
pt
Symptom
g no
Cause Analysis Remedy
● Pressure at both Hi- ● Over-filling of refriger- ● Over-filling of refriger- ● Clean the condenser
in ti
and Lo-pressure ant in the system. Re- ant
● Check the working
sides very high frigerating performance
● Condenser fins clogged condition of fan mo-
inadequate.
● No foam can be ob- or fan motor error. tor
et a
served via the sight ● Insufficient refrigera-

● If the two above
n
glass even when tion of condenser

items are normal,
engine speed drops.
rk er
check the volume

of refrigerant. Add
refrigerant.
Ma t
In

● Air is observed in the refrigerating system
Symptom: Poor refrigeration
NOTE: If refrigerant is added with no evacuation operation performed, the following gauge read-
ing will appear:
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
.
0 8 3
-50 8.5 0
De al
0 08 -76 35
-76
085 0
pt
-01 15 -01 35
MPa MPa
g n
ZX215-1002173
o
in ti

● Pressure at both Hi- and ● Air enters the re- ● Air enters the refriger- ● Check if compressor
et a
Lo-pressure ends very frigerating system ant system oil is contaminated

high or inadequate.
n
● Insufficient evacuation
rk er
● Lo-pressure piping feel- ● Evacuate and add

ing hot new refrigerant.
● Foam is observed
Ma t
through the sight glass

In

● Improper installation of expansion valve/thermal pipe defect (wide opening)
Symptom: insufficient refrigeration
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08
-76 -76 35
085 0
-01 15 -01 35
MPa MPa
.
De al
pt
ZX215-1002174
g no
● Pressure at both ● Expansion valve de- ● Over-filling of ● Check the installation of
in ti
Hi- and Lo-pressure fect, or improper instal- refrigerant in thermal piping

ends very high lation of thermal pipe Lo-pressure
● If thermal piping is normal,
piping
et a
● Frosting or conden- check the expansion valve.

sation on Lo-pres- ● Expansion Replace defective expan-
n
sure piping valve opening sion valve if observed.

rk er
very wide
Ma t
In

● Compressing error
Symptom: No refrigeration
04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1 5
01 07 30
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 - 01 35
MPa MPa
.
De al
pt
ZX215-1002175
g no
● Pressure at Lo-pressure ● Compressor internal ● Compressing fault; ● Repair or replace
in ti
side very high leakage compressor

● Leaking or damaged
● Pressure at Hi-pressure valve, loosened parts
et a
side very low

n
rk er
Ma t
In

4.7.14 Compressor oil
Oil shall be added into the A/C system for lubrication. Compressor oil is solved in the refrigerant
and circulates in the system. When the air conditioning system is shut down, compressor oil will
stay inside the components. If no compressor oil is added into the system when replacing compo-
nents, inadequate lubrication will result. Add compressor oil according to the chart below:
Replaced component
Compressor Condenser Evaporator
Volume (ml) See "CAUTION" below 40 40
ND8# (10P, 10PA, 10S series compressor)
Compressor oil grade
ND9#(TV series compressor)
.
De al
pt
g n CAUTION
● Add oil into a new compressor according to the required volume of the system. When
the compressor is to be replaced, discharge the surplus oil in it.
o
● Over-filling of compressor oil will reduce the refrigerating capacity. Short of compres-
in ti
sor oil in the system will cause compressor abnormality.
● Protect pipe joints and O-rings from contamination when disassembling the compres-
et a
sor.
n
rk er
Ma t
In

4.8 Engine Control
4 5
.
De al
pt
g no
in ti
9
6 7 8
et a
1
n
rk er
Z
ZX215-1002176
Ma t
(1) Battery relay

In
Outline
(2) Battery
● Start and stop the engine only with the en-
(3) Engine start switch gine start switch (3).
(4) Fuel control dial
● The controller (6) receives the signal from
(5) Start motor
the fuel control dial (4) and transmits the
(6) Engine controller drive signal to the throttle motor (8) to
(7) Fuel injection pump control the governor lever angle of fuel
(8) Throttle motor injection pump (7) and control the engine
speed.
(9) Shutdown device
● When engine start switch (3) is turned to
the OFF position, the shutdown device (9)
pulls the flame-out arm on the injection
pump to the “parking” position and cuts the
engine fuel supply. Then, the engine stops.

4.8.1 System operation
Engine startup
● When the start switch is turned to the

START position, the starting signal is trans- (Power)
mitted to the start motor. Then, the start Engine Start motor Starting relay
Start S/W
Fuel ctrl dial
Lo S SW
motor rotates to start the engine. Hi Hi Governor

motor
s
E
(Starting signal)
Safety
L
s
B
relay
Throttle Off
P E
P
Lo B BR C
M B E
When it happens, the controller checks the Throttle On P Alternator Lock

relay
(Starting signal)
(Potentiometer singal)
signal voltage from the fuel control dial and
Drive signal
Shutdown Bat. relay
device Pilot S/W
sets the engine speed to the speed set by Shutdown

relay
the fuel control dial. Controller
.
(Regulating signal
De al
(Start switch ON signal)
pt
ZX215-1002177
g n
Engine speed control
o
● The fuel control dial sends a signal voltage
corresponding to the rotation angle to con-
in ti
(Power)
troller. Fuel ctrl dial

Engine Start motor Starting relay
Start S/W
Lo s
S SW
Hi Hi Governor E
(Starting signal) L B
motor Safety s
relay
Throttle Off
P E
P
B BR C
et a
Lo M
The controller sends a driving signal to the
B E
Throttle On
P Alternator Lock
relay
throttle motor according to the signal volt-
(Starting signal)
(Potentiometer singal)
n
Drive signal
Bat. relay
age to control the fuel injection pump, and Shutdown
device
Pilot S/W
rk er
eventually controls the engine speed.

Shutdown
relay
Controller
(Regulating signal
Ma t
ZX215-1002178
In
Engine shutdown
● When the start switch is turned to the OFF

position, the shutdown device cuts off the (Power)
fuel supply and stops the engine. Engine
Start motor Starting relay
Start S/W
Fuel ctrl dial
Lo s (Starting signal) L
S SW
Hi Hi Governor
motor E
B
Safety s
relay P
Throttle Off
E
P
Lo B E
B BR C
Alternator Lock
Throttle On
relay
(Starting signal)
Shutdown Bat. relay

device Pilot S/W
Shutdown
relay
Controller
(Regulating signal
ZX215-1002179

4.8.2 Components
4.8.2.1 Fuel control dial
140°
9×10°
1
Level 1
Level 10
2 25°
Left limit Right limit

3
.
De al
pt
4
5
g no
in ti
et a
n
6 Yellow
a 5V
rk er
b Blue
VR
Ma t
b
In
a c
Red
c 0V
ZX215-1002180
(1) Knob (4) Ball

(2) Dial (5) Potentiometer
(3) Spring (6) Connector

Function
● Turning of the fuel control dial changes the

resistance of the sliding rheostat inside the
（%）
dial and the voltage signal collected by the 100
controller. The controller calculates the col-
Dial angle
lected signals and drives the throttle motor
via signal output and controls the volume
of the injection pump so that the engine
can run at an optimal speed.
● When throttle voltage is beyond the area,

0 0.25 1.72 4.49 4.75 5（V）
the controller sends out alarm code and Voltage˄V˅
the engine runs at low idle. The area under
.
ZX215-1002181
the sloping line is the abnormality detection
De al
area.
pt
Remark:
g no
The left limit is 0%; and the right limit is 100%.
in ti
et a
n
rk er
Ma t
In

4.8.2.2 Controller
Controller
.
De al
pt
g no
TYPE
in ti
USE FOR
NO
ZX215-1002182
et a
n
Controller port layout

rk er
Ma t
In
........
........ ...................
...................
........
........ ...................
...................
A2 A1 ZX215-1002183

Input and output signals
A1 A1
Pin Input/ Pin Input/
Signal name Signal name
No. output No. output
1 Power ground 53 Rear pump pressure sensor Input
2 Power ground 54 Sensor power ground Input
3 Power ground 55 Sensor power ground Input
4 Power supply(24V constant) Input 56 Sensor power Output
5 Power supply(24V constant) Input 60 Monitor CAN Low
11 Fuel level sensor Input 61 Calibrator CAN High
15 Throttle position signal Input 62 Calibrator CAN Low
19 Engine speed signal Input 66 Coolant temp very high Input
22 RS232 ground 67 R. travel pressure sensor Input
.
23 RS232 receive 68 Swing pressure sensor Input
De al
24 Enable 69 Bucket CURL pressure sensor Input
pt
30 Coolant temperature sensor signal Input 70 Boom RAISE pressure sensor Input
31 Oil temperature sensor signal Input 71 Arm IN pressure sensor Input
33
g n
Backup pilot pressure signal Input 72 Front pump pressure sensor Input
34 Fuel dial signal Input 73 Sensor PWR ground
o
38 Engine speed signal ground 74 Sensor PWR Output
in ti
41 RS232 send 75 Sensor PWR Output

42 CPU mode 76 State indicator
43 Enable 77 Monitor CAN High
48 Engine oil pressure switch Input 78 Monitor CAN Low
et a
49 L. travel pressure sensor Input 79 Calibrator CAN Low

n
50 Bucket DUMP pressure sensor Input 80 Calibrator CAN shield wire

51 Boom LOWER pressure sensor Input 81 Calibrator CAN High
rk er
52 Arm OUT pressure sensor Input
A2
Ma t
Pin Input/
Signal name
No. output
In
82 Travel speed switching solenoid

88 Front pump solenoid valve
89 Rear pump solenoid valve
97 Swing priority solenoid valve
98 Bucket confluence solenoid valve
99 Boom priority 1
100 Boom priority 2
104 Motor drive signal +
113 Motor drive signal -
114 Power ground
115 Power ground
116 Power ground
117 Power ground
118 Power supply(24V constant)

4.9 Electrical Control System
4.9.1 Control function
Engine-Pump composite control function
Pump control function
.
Valve control function
De al
pt
g no
Dual travel speed control
in ti
Electronic control system Engine preheating/overheating alarm

et a
Engine oil under-pressure alarm

n
rk er
Auto-deceleration/acceleration control
Ma t
Engine speed calibration function

In
Self-diagnosis function
NOTE: For detailed information about self-diagnosis function, see "Troubleshooting"

4.9.2 Machine control system diagram
Battery Battery relay Fuel control dial

Fuse
Power ON signal
Start switch
Power supply
Preheating signal
Starting signal
Swing priority signal

1
Power supply
Monitor panel
R. travel signal
Network signal 2
Working mode signal L. travel signal
.
Signal monitor info Travel spd select signal 3
De al
Auto-deceleration signal Boom UP signal
4
pt
Signal monitor info
Boom DOWN signal
5
Arm IN signal
6
g n Fuel level signal
Arm OUT signal
7
Fuel level sensor
o
Hydraulic oil temperature signal Bucket CURL signal
Hydraulic oil temp sensor
8
Bucket DUMP signal
in ti
9
Swing signal
Controller 10
et a
Travel spd select signal

11
n
Bucket confluence signal

17
rk er
Ma t
R.Pump EX press. signal

12
In
F. Pump EX press. signal 13

F. Pump control signal 14
R. Pump control signal
15
Relay 16
Throttle position feedback signal
Motor drive signal
Engine speed
PPC　lock signal
Starting signal
Engine speed sensor Motor Potentiometer
Engine oil pressure

Oil pressure switch
Safety relay Coolant temp sensor
Coolant temp sensor
Charging indicator Alternator Engine
Starting signal
Starting motor
Heater relay Elct. intake air heater
Preheating signal
ZX215-1002184

2 R. travel pressure sensor

3 L. travel pressure sensor
4 Boom UP pressure sensor
5 Boom DOWN pressure sensor

PPC
6 Arm IN pressure sensor Valve
7 Arm OUT pressure sensor
8 Bucket CURL pressure sensor
9 Bucket DUMP pressure sensor
10 Swing pressure sensor
.
De al
pt
F. Pump oil-feed device Work equipment actuator
11
g no
17
in ti
PPC Basic pressure
13
et a
12
Swing Travel
n
PPC Lock Bucket

solenoid confluence priority speed
16 solenoid solenoid solenoid
valve valve valve
valve
rk er
15
14 Control valve
Ma t
ports
F. Pressure sensor
R. Pressure sensor
PnA2 XBp2
Proportional valve
Proportional valve
PsP
In
Main valve
Servo Servo
F R
Travel motor
Main pump
R. Pump oil-feed device Swing motor
Work equipment actuator Travel motor

ZX225-1102049
Remark:
The diagram above illustrates the electrical control system. For hydraulic circuit diagram, see Hy-
draulic System section.

4.9.3 Engine and pump composite control function
PPC valve Operator cab

Monitor
Travel Travel MAX
Boom UP/DOWN
Arm IN/OUT
Bucket DIG/DUMP
Swing
MIN
Fuel control dial
MC Controller input
Pressure Option pressure
H/S/L/B sensor
sensor
.
Auto-idle cancel
De al
Pilot oil pressure

Travel speed swithing
pt
Alarm output
g no
in ti
Main control valve

et a
n
Pressure Engine chamber

sensor
rk er
KC controller
P2
P1
Ma t
Engine
Oil-feed
Pump adjustment
In
Pump proportional
pressure reduce
solenoid valve
Throttle motor
CAN path
Potentio- Motor
meter
R. Pump control angle
F. Pump control angle
Engine speed
Calibrator
SW LED Actual throttle position feedback
MEMORYON
H S L A/I
Control motor
LED
DOWN UP
7 RPW
LED
SW
PWR resouce DC24V H S L A/I
Fuel, coolant temp and others
(Battery)
ZX215-1002186

Function
● This function allows the operator to select

a working mode according to the job to
be performed and change engine power
Engine torque T
output. Four different working modes are
H
available: H, S, L and B. To select a work- S
ing mode, use the working mode selector L
switch on the machine monitor.
● The main controller controls the pump so

that it can absorb all the torque at the out-
put points of the engine depending on the
pump absorption torque specified for each Engine speed N
.
mode, rotation set by the fuel control dial,
De al
ZX215-1002193
and actual engine speed.
pt
g n
Specifications H
o Engine powerKW
S
H mode
in ti
L
Engine
~1600 1600~1800 1800~2250
speed
et a
Power (KW) 60 84 115

n
S mode
rk er
Engine
~1600 1600~2250
speed Engine speed N
ZX215-1002194
Power (KW) 60 84
Ma t
L mode
In
Engine
~2250
speed
Pump deliveryQ
H
Power (KW) 60
S
Pump output pressureP

ZX215-1002195

Control method of each working mode
H mode
● The matching point of H mode: rated
Engine torque T
speed 114kW/2050rpm
● If pump load increases and pump pressure

rises, engine speed drops. In this case,
engine speed will rise to near the match-
ing point, allowing the pump controller to
reduce pump discharge. On the contrary, if
pump load decreases and pump pressure
drops, pump controller will continue to in- Engine speed N
.
De al
crease pump discharge until engine speed ZX215-1002190
pt
reaches the matching point.
g no Engine powerKW
in ti
et a
n
rk er
Engine speed N
ZX215-1002191
Ma t
In
Pump deliveryQ

ZX215-1002192

S mode/B mode/L mode
Power output rate of at each working mode
Engine torque T
H
Mode S L B S
L
Power output rate 90% 80% 70%
● At this time, the controller keeps the pump

oil-suction torque in line with the stabling
motor curve, and controls engine speed
through combined control of the engine Engine speed N
and pump. ZX215-1002193
.
De al
pt
g n H
Engine powerKW
S
o
L
in ti
et a
n
Engine speed N
rk er
ZX215-1002194
Ma t
In
Pump deliveryQ

ZX215-1002195

4.9.4 Pump control function
Engine Main Press.sensor Press.sensor

pump
Fuel injection Throttle
pump motor F R
M
P Speed
Servo Servo
sensor
.
De al
pt
g n
(Throttle position feedback signal)
o
Proportional Proportional
valve valve
in ti
Fuel control dial

(Engine speed signal)
(Control signal)
(Control signal)
Hi
(Motor drive signal)
et a
Lo
n
rk er
Monitor
Ma t
Controller
In
(CANbus)
Bucket DUMP signal
Boom DOWN signal

Bucket DIG signal
Boom UP signal
Arm OUT signal
R. Travel signal
L. Travel signal
Arm IN signal
Swing signal
ZX215-1002196

4.9.4.1 Electrical positive flow control
Pump 1
delivery
amount
Boom RAISE PPC pressure

Pump 1
delivery
amount
Arm IN PPC pressure
Pump 1
.
De al
delivery
amount
pt
Arm OUT PPC pressure
Pump 1
g n
delivery Corresponding
o
amount delivery output
MAX
in ti
Bucket CURL PPC pressure

Pump 1
delivery
et a
amount
n
Bucket DUMP PPC pressure

rk er
Pump 1
delivery
amount
Ma t
Swing PPC pressure

In
Pump 1
delivery
amount
L. Travel PPC pressure
ZX215-1002197

Pump 2
delivery
amount
Boom RAISE PPC pressure
Pump 2
delivery
amount
Arm IN PPC pressure
.
Pump 2
De al
delivery
pt
amount
Arm OUT PPC pressure

Pump 2
g no
delivery Corresponding
amount delivery output
MAX
in ti
Bucket CURL PPC pressure

Pump 2
et a
delivery
amount
n
Bucket DUMP PPC pressure

rk er
Pump 2
delivery
amount
Ma t
Boom LOWER PPC pressure

In
Pump 2
delivery
amount
R. Travel PPC pressure
ZX215-1002198

Function
● Use the joystick pilot pressure signal di-

rectly as the hydraulic pump discharge
control signal. Pilot pressure is applied on
the valve stem and, on the other hand, is
collected by the controller. The controller
keeps the discharge amount of the hydrau-
lic pump at the specified value of the cor-
responding pilot pressure according to the
functional relation between the set hydrau-
lic pump discharge amount and pilot pres-
sure. During combined operation, the set
discharge amount of each operation shall
.
De al
be added.
pt
Operation
g no
● When the work equipment is operating, the
in ti
controller collects the signal of pilot pres-

sure sensor, and determines the control
discharge amount of pump 1 and pump 2
et a
according to the pressure signal.

n
rk er
Ma t
In

4.9.4.2 Constant power control
Function
● Calculation of theoretical maximum dis-

charge amount of the pump. The system
applies constant power control. The two
Q
adjustor act together hydraulically, and Flow Pump P-Q curve
keep two executing unit of the same speci- P0
PMax
fication and acting together in synchroni-
zation. The change of pump discharge is
determined by the sum of operating pres-
PMax
sure of the two hydraulic pumps P∑ . When
.
is met, the sum of the
De al
P
power of the two hydraulic pumps remains
pt
Pressure
constant below the power of the engine.
g n ZX215-1002199
o
Operation
in ti
● When the work equipment is working, the

controller collects the throttle gear signal,,
a constant current value is provided and
et a
pump power control is achieved.

n
rk er
Ma t
In

ESS control
Function
● Changing of the engine speed due to load

change controls the pump power, and en-
gine output can be used more efficiently.
(This function can also prevent the engine
from losing control when the machine is
operating under harsh conditions (eg. high
- altitude area).
Operation
.
De al
The engine control panel controls the target
pt
operating speed of the engine.
g n
● The engine controller collects the actual
speed signal from the ECM, and preforms
o
a closed loop control with the target oper-
in ti
ating speed. Then, the controller involves

the output of closed-loop control with the
calculation of the solenoid valve control
et a
signal, and sends the final adjusting cur-

rent signal to the pump proportional sole-
n
noid valve.
rk er
● The solenoid valve feeds pilot pressure oil

to the pump adjustor according to the sig-
nal of the controller, and controls the pump
Ma t
discharge amount.
In

4.9.5 Valve control function
Swing priortity Bucket Confluence
Main valve
Engine Press.sensor Press.sensor

Main
Fuel injection Throttle pump
pump motor F R
.
Speed
De al
P Servo Servo
sensor
pt
g no
in ti
Proportional Proportional
valve valve
Fuel control dial

et a
(Engine speed signal)
(Control signal)
(Control signal)
Hi
n
Lo
rk er
Ma t
In
Monitor
Controller
(CANbus)
Boom DOWN signal
Bucket DUMP signal
Bucket DIG signal
Boom UP signal
Arm OUT signal
R. Travel signal
L. Travel signal
Arm IN signal
Swing signal
ZX215-1002200
Valve control function
● Bucket flow control
● Swing priority control

4.9.5.1 Bucket flow control
Function
● Control the pump swash plate angle ac- Swash plate angle
cording to the operation of bucket control
lever.
Max
Min
Bucket control lever
PPC pressure
.
ZX215-1002201
De al
pt
Operation g n Bucket confluence
● When the bucket control lever is operated, proportional
o
the controller collects the signal from the valve current
bucket DUMP pressure sensor and bucket
in ti
CURL pressure sensor, and controls the 750mA
bucket confluence proportional valve.

et a
300mA
n
Bucket control lever

PPC pressure
rk er
ZX215-1002202
Ma t
In

4.9.5.2 Swing priority control
Function
● Pressurized oil from pump 1 bypasses

bucket 1 valve spool, and flows first to
swing motor valve spool to activate swing
first.
Operation
● When signals from pump 1 pressure sen-

sor, arm pressure sensor and swing pres-
.
sure sensor meet the following conditions,
De al
the controller activates the solenoid valve.
pt
The solenoid valve conducts pilot pressure
oil to arm flow controller and limits the al-
g n
ternate circuit of arm 1 valve spool. Swing
o
valve spool first ensures swing motor
power, preventing the counter acting force
in ti
when the arm is retracting from affecting

the positioning of the upper swing struc-
ture.
et a
n
Operating condition
rk er
● Swing pressure sensor: signal output avail-

able
Ma t
● Arm pressure sensor: signal output avail-

In
able

4.9.6 Duo travel speed control
Travel motor
Regulator Regulator
L. Travel pressure sensor
R. Travel pressure sensor
.
De al
Main valve Travel Speed
pt
solenoid valve
g n Engine
Injection Throttle Main pump
o
pump motor F R
in ti
M
P Servo Servo
et a
n
Fuel control dial

rk er (Motor drive signal)
(Control signal)
(Control signal)
Hi
Lo
Ma t
In
Monitor
Controller
(CANbus)
ZX215-1002203

Function
● Control travel mode.
Operating condition
● When Hi speed travel mode on the monitor

is enabled.
Operation
● When the travel mode is set at LO speed,

the swash plate angle of the travel motor is
the largest, and travel speed is low.
.
De al
● When the controller receives the signal
pt
from the travel pressure sensor under the
conditions below, it activates the solenoid
g n
valve. Then, the solenoid valve conducts
o
pilot pressure oil to the swash plate angle
control valve of the travel motor, and re-
in ti
duces the swash plate angle to increase

travel speed.
et a
n
Remark:
rk er
When one side of the tracks is lifted off the

ground by the work equipment and rotating,
pressure at one side of the pump increases,
Ma t
which makes the lifted track rotate very fast.

When the machine is traveling under Hi speed
In
mode, even if work equipment is being op-

erated (work equipment pressure sensor is
switched ON), travel mode remains in Hi travel
mode.

4.9.7 Engine preheating/overheating alarm
Start switch
Heat
Preheat s/w Preheat relay Main valve
Engine Main
Throttle motor pump
Coolant F R
.
tempe
De al
sensor
pt
M
g n P Servo Servo
o
in ti
Fuel control dial

(Control signal)
(Control signal)
Hi
et a (Motor drive signal)
Lo
n
rk er
Monitor
Ma t
(CANbus) Controller
In
ZX215-1002204

4.9.7.1 Engine preheating
Function
● Preheating control
Operation
● This function shall be used in combination

with the preheating switch located on the
right armrest. Turn the engine start key
counterclockwise to the HEAT position and
hold on, the engine will start preheating.
When released, the key will return to the
.
De al
OFF position automatically and preheating
pt
stops.
g n
Operating condition
o
● Power ON. Start key set at the HEAT posi-
in ti
tion.
● Preheating switch: ON
et a
n
rk er
Ma t
In

4.9.7.2 Engine overheating alarm
Function
● When engine coolant temperature be-

comes excessively high (above 110°C)
during operation, overheating alarm will be
displayed on the monitor screen.
Operation
● The controller collects signal from the cool-

ant temperature sensor. When coolant
temperature rises too high, alarming infor-
.
mation will be generated and transmitted
De al
to the machine monitor.
pt
g n
Operating condition
o
● Power ON.
in ti
● Coolant temperature above 110°C.

et a
4.9.8 Engine oil under–pressure alarm

n
rk er
Function
● The engine controller collects signal from

Ma t
the engine oil pressure sensor. When en-

gine speed exceeds 600 rpm, if oil pres-
In
sure is too low, alarming information will be

generated and transmitted to the machine
monitor. The alarm indicator lights up when
the monitor receives the signal.

4.9.9 Auto deceleration/acceleration control
Right joystick
Boom Bucket
DOWN
OUT
UP
IN
Engine
Swing Left joystick Arm

Engine
throttle
CURL
DUMP
controller
R
L
(Potentiometer signal)
.
De al
Fuel control dial L.Travel R.Travel
pt
Travel lever
Forward
Reverse
Forward
Reverse
g n (Throttle signal)
Monitor
o
in ti
Controller
(CANbus)
et a
Control lever signal

n
rk er
ZX215-1002205
Ma t
In

Function
● If all the control levers are neutralized, en-

gine speed will drop to the medium level
automatically to reduce fuel consumption
and noise.
● If any of the levers is operated, the engine

speed rises to the set level instantly.
Operation
● About 3 second after all control levers are

neutralized, engine speed will drop to the
.
Speed (rpm)
De al
first deceleration level about 100 rpm lower
pt
Set rpm
than the set speed. After another 3 sec- Drop 100rpm
onds engine speed enters low speed (1400

g n Deceleration
rpm) to reduce the loss of the hydraulic (1350rpm)
system and engine wear, and reduce fuel 3s Less than 1 S

o
less than 2 S
consumption and noise. When the control
Time (s)
in ti
lever is operated again, the engine speed
Operated
rises instantly to the previous level. Operated Unoperated
Control lever
● If any control lever is operated while the ZX215-1002206

et a
engine speed is kept at decelerated level,

n
engine speed will rise instantly to the level

set by the fuel control dial.
rk er
Ma t
In

4.9.10 Engine speed calibration function
Swing pripority Bucket confluence
Main valve
Engine Pressure sensor Pressure sensor

Main pump
Injection Throttle
pump motor F R
.
Speed
De al
P sensor Servo Servo
pt
g no
in ti
(Throttle position feedback signaL)
Fuel control dial

et a
(Engine speed signaL)
(Control signaL)
(Control signaL)
(Motor drive signaL)
Hi
n
Lo
rk er
Ma t
In
Monitor
Controller
(CANbus)
Bucket DUMP signal
Boom DOWN signal
Calibtator
Bucket DIG signal
SW LED
Boom UP signal
Arm OUT signal
R. Travel signal
MEMORYON
L. Travel signal
Arm IN signal
Swing signal
H S L A/I
LED
DOWN UP
7 RPW
LED
SW
H S L A/I
ZX215-1002207

Function
● Set the maximum engine speed under

each working mode. This set speed is the
standard to control engine speed.
Operation
● Calibrating procedure for positive flow exca-

vators.
1) Selection of fixing point of throttle motor

soft shaft
.
De al
2) H, S, L maximum speed calibration, and A/
pt
I speed calibration.
g n
3) Turn the dial on the calibrator counter-
clockwise to the end
o
4) Power OFF
in ti
5) Set the calibrator to "Monitor mode", power

on and check the result.
et a
Remark:
n
Memory SW up: Calibration mode;

rk er
Memory SW down: Monitor mode

Ma t
For more information, see “Engine Speed -

Test and Calibrate” on page 6-3.
In

4.9.11 Electrical Components
4.9.11.1 Pump pressure sensor
Connection diagram
No. Signal name
A PWR +5V
.
Terminal C B Output
De al
Terminal B
pt
C
g no
Terminal A
in ti
ZX305-1002066
Operation
et a
● The relationship between the pressure ap- (V)

n
plied on the sensor (P) and output voltage

Sensor output voltage (E)
(E) is shown in the right diagram.

rk er

Ma t
In

(MPa)

Oil pressure (P)
ZX215-1002209

4.9.11.2 Pilot pressure sensor
Connection diagram
No. Signal name
A PWR +5V
Terminal C B Output
Terminal B
C
.
De al
pt
Terminal A
g n
ZX305-1002066
o
in ti
Operation
● The relationship between the pressure ap-

plied on the sensor (P) and output voltage
et a
(E) is shown in the right diagram. (V)

n

rk er
Sensor output voltage (E)

Ma t

In

(MPa)

Oil pressure (P)
ZX215-1002210

4.9.11.3 Engine speed sensor
2 1
ZX215-1002211
.
De al
pt
Function g n
● The engine revolution sensor is installed to
o
the ring gear of the engine flywheel. It elec-
trically calculates the number of the gear
in ti
teeth which pass in front of it and transmits

the result to the engine controller.
et a
Operation
n
● Measure the resistance between terminal

rk er
1 and terminal 2 when it is in service.
Standard value (@25°C) 2.3±0.2 kΩ

Ma t
● If the measured value exceeds the stan-

In
dard value, replace the sensor.
CAUTION
● If the engine speed sensor is not tight-
ened to the specified torque, the sensor
may send out no signals. Tighten the
engine speed sensor to the specified
torque.

4.9.11.4 Coolant temperature sensor
2
1
.
De al
ZX215-1002212
pt
(1) Sensor g n
(2) Connector
o
in ti
Function
● The output resistance of the engine cool-

ant temperature sensor changes with the
et a
coolant temperature. The controller collects

n
and processes coolant temperature signals

and works out the coolant temperature.
rk er
Specifications
Ma t
50°C 80Ω (Ref.)

In
60°C 56.3Ω
Standard 80°C 29.5±10Ω
value 100°C 16.5Ω
106°C 14.3±0.5Ω
120°C 10Ω(Ref.)

4.9.11.5 Fuel level sensor
1 2 3 4
.
De al
pt
ZX215-1002246
(1) Float
g n (3) Casing
(2) Lever (4) Coupler
o
in ti
et a
n
rk er
Ma t
In

4.9.11.6 Oil pressure switch
1 2 3
㥋䕑
य़࡯
.
De al
pt
g n ZX215-1002214
(1) O-ring
o
(2) Sensor
in ti
(3) Connector
et a
Function
n
● The oil pressure switch is installed on the

outlet circuit of the oil filter. It detects oil
rk er
pressure and transmits warning signals to

the controller.
Ma t
In
Specifications
● Type of contact: Normally closed type
● Operating pressure: 1.9kg

4.10 Monitoring System
Monitor CAN signal
Controller
.
De al
pt
Power
g no
Sensor
in ti
et a
n
Battery
rk er
W13053001
● The state of the machine is monitored 1. Alert information when a machine fault is
Ma t
by the sensors mounted on the machine detected.

components. The controller processes the
In
signals and transmits the signals to the 2. Operating condition (coolant temperature,
monitor display, informing the operator of fuel level, etc. )
the machine condition. ● The machine control system can be oper-
● Information on the monitor display includes ated using the switches and keys on the
primarily: monitor panel.

4.10.1 Machine monitor
$ %
.
De al
pt
g n
F1 F2 F3 F4 F5
o
Esc Enter
in ti
WX215-1204002H
et a
Outline
n
● The monitor displays various kinds of items

rk er
and is used by the operator to select a ● When the monitor is turned on, blinking
working mode. strips may appear on the LCD screen.
This is normal.
Ma t
● The monitor has a CPU which processes,

displays, and outputs information.
In
Input and output signals

● The monitor has an LCD (Liquid Crystal
Display) screen. No. Signal name Input/output
NOTE: 1 Digital input A Input

3 CAN high
● The LCD may have black spots (which do
4 CAN low
not light up) or bright spots (which stay on).
7 Digital input B
Products having 10 or less black or bright
spots conform to the product specification; 8 Trigger power source (24V)
such condition is quite normal. 9 Power source (24V)
10 Grounding
● Continuous operation of the monitor may
11 Digital input C
cause the LCD to display bright blue spots
12 Grounding
on a black background; it is quite normal.

4.10.2 Monitor functions
The front side of the machine monitor is made

up of three sections:
A. Warning and signal indicators A

$ %
B. Display screen
C. Key pad
.
De al
pt
g n
F1 F2 F3 F4 F5
o
C Esc Enter
in ti
XP13031506
et a
n
Warning and signal indicators

rk er
● When a machine fault occurs, the warning

indicator lights up, reminding the user to
Ma t
check and address the fault.

In
$ %
XP13031505

Screen display
The LCD display is where monitor items are

shown. This display is also the interface where
most monitor operations are performed. Items
on a normal operation display include:
1. Working mode indicator

2. Coolant temperature gage
Sany Hydraulic Excavator
3. Fuel level gage
1 6 10
4. Failure code
5. Total service hours 2
.
De al
C H
6. Function icons
pt
7. System time (Hr: Min: Sec)
g n 3
8. Date (YY:MM:DD) E F
4 9
o
9. GPS signal 8
5 KP ( 7
in ti
10. Engine speed level (1 to 11)

6 6 AUTO
n/min
XP13032601
et a
n
rk er
Key pad
Ma t
The key pad is composed of 5 function keys

and six navigation keys.
In
1 F1 F2 F3 F4 F5
Esc Enter
2
XP13031502

1. Function keys
Functions of the five keys ( F1 , F2 , F3 , F4 , F5 ) are indicated by the function icons above them
on the screen.
Function keys and icons
Function key Icon Function Operation interface
S , H
Working mode selection Home page
L , B
Select the next item; Information Menu page
Go to the next page; Engine and Throttle Signal page, etc.
F1
Increase password value Password Entry page
.
De al
Save System Time Calibration page, etc.
pt
g n Lower monitor brightness Brightness Adjustment page
Switch between Auto idle and Non
AUTO
or Home page
auto idle
n/min n/min
o
Move the cursor to the right Password Entry page
in ti
F2
Enter a selected entry Information Menu page, etc.

et a
Increase monitor brightness Brightness Adjustment page

Switch between High and Low
n
or Home page
travel speed
rk er
Password validation Password Entry page

F3
Confirm the validity of a password Password Entry page
and, if it’s correct, enter the de-
Ma t
sired page.
In
Save monitor brightness Brightness Adjustment page

Go to “Fault Information” page Home page
Enter/Confirm Same as Enter
F4 Go to Brightness Adjustment page Password Entry page
Go to System Setup page Information Menu page
Go to Information Menu Home page

F5
Return to Home page, Information
Password Entry page, etc.
Menu or System Setup page
Machine Configuration Calibration
Save
page
Go to System Unlock page Lockout Information page
NOTE: When no icon is displayed above a function key, this key is disabled.

2. Navigation keys
Navigation keys Function
Enter Enter/Confirm
ESC Return
Select the item above (returns to the bottom item after the top item); or increase the
value where the cursor blinks.
Select the item below (returns to the top item after the bottom item); or decrease the
value where the cursor blinks.
Move the cursor to the left (returns to the right end digit after the left end digit).
.
De al
Move the cursor to the right (returns to the left end digit after the right end digit).
pt
g n
4.10.3 Monitor operation
o
in ti
1. Home page
The Home page is the normal operation display of the monitor. Items on this page include:
truck load counter, working mode, speed level, coolant temperature, fuel level, service hours,
et a
clock, fault code, etc..

n
rk er
Operation
Working mode selection (1)

Sany Hydraulic Excavator
Ma t
● Press F1 switch between S, H. L and B

6
mode.
In
NOTE: S mode is the default working

C H
mode.
Auto-idle and Non auto-idle mode (2)
● Press F2 to switch between auto-idle and E F
Non auto-idle mode.

KP (
Auto-idle mode is indicated by AUTO
n/min
.
6 AUTO
n/min
Non auto-idle mode is indicated by n/min .

XP13032602
NOTE: Auto-idle mode is the default mode.

When neither of the joysticks are operated

for 5 seconds, the engine enters the idling
state automatically in order to save fuel
and reduce noise.
High and low travel speed (3)
● Press F3 to switch between high and low

travel speed.
High travel speed is indicated by .
Low travel speed is indicated by .
NOTE: Default travel speed is Low.
.
De al
Fault Information (4)
pt
● Press F4 to go to “Fault Information” when
a fault occurs.
g n
NOTE: When the ECU detects an error in
o
the machine, a fault code will appear on
in ti
the monitor display. The tick icon on the

bottom will turn red.
et a
Information Menu (5)

n
● Press F5 to go to the Password Entry

page before accessing the “Information
rk er
Menu” page.
Ma t
In

2. Information Menu password entry
A 5-digit password is required to access the

“Information Menu”. You can ask your local
dealer to obtain this password.
Operation
1. Press F1 to change the number where the

cursor blinks in an ascending order. You
can also use or to increase or de-
Information Menu
crease the number.
2. Press F2 to move the cursor to the right.

You can also use or to move the
.
Please enter the password
De al
cursor to the left or to the right. ＊　＊　＊　＊　＊
pt
NOTE: The cursor moves back to the left
g n
end side after the right end side.
o
3. When all the five digits of the password
have been entered, press F3 or Enter . If the
in ti
password is correct, the display moves to

the “Information Menu” page; if not, please
try again.
et a
XP13031501
4. Press F5 or ESC to return to the Home

n
page.
rk er
5. Press F4 on this page to go to Brightness

Adjustment page.
Ma t
In

3. Information Menu
The information menu is a list of system func-

tions. On this page, you can select and access
any of the items on the list. Information Menu
Operation
Running parameter
● Press F1 to select the item below the high-
Fault information
lighted one. The highlighter returns to the
Throttle installation
top after the bottom item. You can also use
System language
and to move the highlighter up and
System time setup
down.
GPS monitoring
.
● Press F2 or Enter to access the selected en-
De al
try. Engine, pump and valve parameters
pt
● Press F5 or
g n ESC to return to the Home
page.
XP1251203007
o
● Press F4 on this page to go to the Pass-
in ti
word Entry page before accessing the Sys-

tem Setup page.
et a
NOTE: Once an entry on the list is highlighted,

n
an introductory hint will appear on the bottom

of the display giving a short description of the
rk er
selected entry. These hints include:
● Running parameters of the engine, main

Ma t
pup and main valve

In
● Fault code and description
● Throttle installation assistance
● System language selection
● System time setup
● GPS monitoring information

4. Engine & Throttle Signal
Select “Running Parameter” on the Informa-

tion Menu page and press F2 or Enter , and the
display moves to Engine & Throttle Signal Engine & Throttle Signal
page. This page is a real-time display of the
running parameter of the engine and throttle. Coolant temp °C:
Fuel level %:
Oil press kPa:
Operation
Throttle gear:
● Press F1 to go to “Pilot Pressure Signal” Eng speed rpm:
page.
Gear position V:
● Press F5 or to return to the “Information
.
ESC
Throt position V:
De al
Menu”.
pt
g no
XP1251203008
in ti
5. Pilot Pressure Signal

et a
n
This page is a real-time display of the pilot

pressure signal of the hydraulic system.
rk er
Operation Pilot Pressure Signal
● Press F1 to go to “Main Pump and Main

Ma t
Boom UP kg:
Valve Signal” page. Boom DOWN kg:
In
Arm IN kg:
● Press F5 or ESC to return to the “Information Arm OUT kg:
Menu”. Bucket DIG kg:
Bucket DUMP kg:
Swing kg:
Travel L kg:
Travel R kg:
XP2051203009

6. Main Pump & Main Valve Signal
This page is a real-time display of the main

pump and main valve signals of the hydraulic
system. Main Pump & Main Valve Signal
Operation
Pump1 press kg
● Press F1 to go to “Engine & Throttle Sig- Pump2 press kg
nal” page. Prop valve1 current mA
Prop valve2 current mA
● Press F5 or ESC to return to the “Information
Bucket confluence valve ż
Menu”.
Swing priority valve ż
Boom priority valve ż
.
De al
Hi/Lo speed switch ż
pt
g no
XP2051203010
in ti
7. Fault Information
et a
Select “Fault Information” on the Information

n
Menu page and press F2 or Enter , and the dis-

play moves to Fault Information page. This Fault Information
rk er
page lists important machine fault information.

Current fault code:XXX
XXX:
XXX:
Ma t
XXX:
Operation XXX:
XXX:
In
XXX:
● Press F1 to go to the next page. XXX:
XXX:
XXX:
● Press F5 or to return to the “Information

XXX:
ESC
XXX:
Menu”.
XXX:
XXX:
XXX:
XXX:
XXX:
XXX:
XP13041501

8. Throttle Installation
Select “Throttle Installation” on the Information

play moves to Throttle Installation page. This Throttle Installation
page displays throttle installation assistance
function.
Current gear N
Operation Eng speed rpm 1200 ?
● Press F2 to switch between auto-idle and Gear position V

full speed.
Throttle position V
● Press F3 to select high or low travel
.
speed.
De al
pt
● For machines equipped with SYFCS con- AUTO
rpm
trollers, press F4 to switch between rpm n/min
g n
(blue) and rpm (red).
XP2051203013
o
● Press F5 or ESC to return to the “Information
in ti
Menu”.
NOTE: For machines equipped with SYFCS

controllers, when engine speed calibration is
et a
not successful, a question mark will appear.

n
rk er
9. System Language
Ma t
Select “System Language” on the Information System Language

In
play moves to this page.
Operation Ё᭛㋏㒳
English Systems
● Press F2 to select 中文.
● Press F3 to select English.
● You can also use or to select a sys-

tem language on the list.
● Press F5 or ESC to return to the “Information Ё᭛ (QJ
Menu”.
XP2051203014

10. System Time Setup
Select “System Time Setup” on the Informa-

tion Menu page and press F2 or Enter , and the
display moves to this page. You can set sys- System Time Setup
tem time on this page.
Operation Current time and time zone:
1234·12·12 12:12:12 W
● Use and to change the number
where the cursor blinks.
Setup time and time zone:
1234·12·12 12:12:12 W
● Use and to move the cursor.
● Press F1 or Enter to save adjusted time.
.
De al
● Press F5 or ESC to return to the “Information Use > Ĺ @ > Ļ @ > ĸ @ > ĺ @ t o adj ust syst em t i m e
pt
Menu”.
g n
NOTE: When F1 or Enter is pressed, the screen
XP2051203015
displays “Setup Finished” on the bottom. If
o
system time has been adjusted, it cannot be
in ti
adjusted again until the system is re-ener-

gized.
et a
11. GPS Monitoring

n
rk er
Select “GPS Monitoring” on the Information

Menu and press F2 or Enter to view this page.
GPS Monitoring
Ma t
Longitude ° ˖
Operation
In
Latitude °˖
● Press F5 or ESC to return to the “Information Elevation m:
Speed Km/h:
Menu”.
Satellite No.:
Comm index˖
Remark: S/N ratio 1˖ G%
S/N ratio 2˖ G%
● Longitude: “E” stands for “East”, while “W” S/N ratio 3˖ G%
for “West”. S/N ratio 4˖ G%
● Latitude: “N” stands for “North”, while “S”

for “South”.
XP130426011
● Altitude: “P” means “Above Sea Level”,
while “N” means “Below Sea Level”.

● The blue-white bars show signal-to-Noise

ratio ranges from 0 to 99.
● When the altitude is nonzero and the longi-

tude and latitude is zero, it means that the
system is receiving GPS data, yet still in
the process of precise positioning.
● GPS is normal when the signal indicator

shows 1023, otherwise it is abnormal when
the signal indicator shows 615.
● When the signal indication changes to 0

from 7, a connection failure occurs either
in the SIM card or in the antenna.
.
De al
pt
● When the signal indication changes to
0 from 15, it is either because the GPS
g n
service is not available, or the SIM card
charge is overdue, or the GPS network is
o
abnormal.
in ti
● When the signal indication changes to 0

from 31, it is because the monitoring cen-
ter suspends.
et a
n
12. Brightness Adjustment

rk er
Press F4 on the Information Menu Password

Entry page to go to Bright Adjustment page.
Ma t
This page is used to adjust monitor screen Brightness Adjustment

In
brightness.
Brightness: 20%
Operation
● Press F1 to decrease brightness level.

The progress bar moves to the left side.
Minimum brightness is 10%.
● Press F2 to increase brightness level. The

progress bar moves to the right side. Maxi-
mum brightness is 100%. Tips: Use F3 to save brightness value.
● Press F3 to save brightness adjustment.
● Press F5 to return to the “Information XP2051203029

Menu”.

13. System Setup password entry
Press F4 on the Information Menu page to en-

ter the Password Entry page before accessing
the System Setup page. System Setup
Operation
1. For password entry method, see Informa-
tion Menu Password Entry page.

.
the “System Setup” page; if not, please try
De al
again.
pt
3. Press F5 org n ESC to return to the Home
page. XP130426012
o
in ti
NOTE: Contact your local dealer to obtain this

password.
et a
14. System Setup

n
This page is used to set up machine configu-

rk er
ration.
Operation System Setup

Ma t
● Press F1 to select the item below the high-

In
Machine configuration
lighted one. The highlighter returns to the Service hour setup
top after the bottom item. You can also use
Machine configuration setup
and to move the highlighter up and
Hydraulic oil temperature
down.
● Press F2 or Enter to access the selected en-

try.
● Press F5 or ESC to return to the Home

page.
XP2051203016

15. Machine Configuration password entry
Select Machine Configuration on the System

Setup list and press F2 or Enter , and the display
moves to the Password entry page before ac- System Setup
cessing the Machine Configuration page.

Operation

.
De al
pt
the “Machine Configuration” page; if not,
please try again.
g n
3. Press F5 or to return to the “System XP13060801
o
ESC
Setup” page.
in ti
et a
16. Machine Configuration

n
You can view machine configuration informa-

rk er
tion on this page.

Machine Configuraiton
Operation
Ma t
● Press F5 or ESC to return to the “System Machine model：

In
Setup” page.
Machine No.:
Engine model:
Hydr system model:
Controller model:
XP13041502

17. Service Hour Setup password entry
Select “Service Hour Setup” on the System

Setup list and press F2 or Enter , and the display
moves to the Password entry page before ac- System Setup
cessing the Service Hour Setup page.
Operation Please enter the password


.
password is correct, the display moves
De al
to the “Service Hour Setup” page; if not,
pt
please try again.g n
3. Press F5 or ESC to return to the “System
XP13060802
Setup” page.
o
in ti
18. Service Hour Setup

et a
This page is used to set up machine service

n
hours.
rk er
Service Hour Setup

Operation
Current service hour
● Use and to change the number
Ma t
where the cursor blinks. 100 h 50 m

In
● Use and to move the cursor. Setup service hour
● Press F1 or Enter to save adjusted time. 100 h 50 m
● Press F5 or ESC to return to the “System

Setup” page.
Use >Ĺ@>Ļ@>ĸ@>ĺ@ to adjust service hour
NOTE: When F1 or ENTER is pressed, the

screen displays “Setup Finished” on the bot-
tom. If system time has been adjusted, it can- XP2051203021
not be adjusted again until the system is re-
energized.

19. Machine Configuration Setup password

entry
Select “Machine Configuration Setup” on the

System Setup list and press F2 or Enter , and the
display moves to this Password entry page. ㋏㒳䆒㕂
Operation 䇋䕧ܹᴎ఼䜡㕂䆒ᅮᆚⷕ˖

.
De al
pt
the “Machine Configuration Setup” page; if
not, please try again.
g n
3. Press F5 or to return to the “System
o
ESC
XP13060803
Setup” page.
in ti
et a
n
rk er
Ma t
In

20. Machine Configuration Setup
This page is used to set up machine configu-

ration after installation of the monitor.
Operation Machine Config Setup
● Press F1 to change machine model. Machine model:
● Press F2 to change engine model. Engine model:
● Press F3 to change hydraulic system Hydraulic model:

model.
Control model:
● Press F4 to change controller model.
.
De al
Machine No.:
● Press F5 to save machine configura-
pt
Use>Ĺ@>Ļ@>ĸ@>ĺ@ to set up machine number
tion. The screen displays “Setup finished.
Mach Eng Hydr Cont
Please re-energize the system.”
g n
● Press Enter to move the cursor between dif- XP13041503
o
ferent parts in the machine number.
in ti
● Use and to increase and decrease

the selected machine number by 100 each
time.
et a
● Use and to increase and decrease

n
the selected machine number. One quick

rk er
pressing increase or decrease the number

by 1. Long pressing increase or decrease
the number in a quicker pace.
Ma t
● Press ESC to return to the “System Setup”

In
page.

Remark:
The machine serial number is composed of

4 parts: 1) Production year, 2) Product code,
3) Tonnage code, 4) Alteration code, 5) Serial
number, and 6) Tail number “8”.
1) Press Enter to move the cursor to different

part (Production year, Product code and
Serial number) in the machine number.
2) When the cursor moves to Production year

and Alteration code, press and to
increase or decrease Production year and
Alteration code by 1 each time.
.
De al
pt
3) When the cursor moves to Tonnage code,
press and
g n to increase or decrease
tonnage code by 1 each time; or press
and to increase or decrease tonnage
o
code by 100 each time.
in ti
4) When the cursor moves to Serial number,

press and to increase or decrease
this number by 1 each time. Long press-
et a
ing to change the number in a quick pace.

n
Press and to increase or decrease

this number by 100 each time.
rk er
5) The machine number has 4 adjustable dig-

its. Use and to switch between the
Ma t
four digits, and use and to change

the value on a digit. The value of the first
In
digit from the left could be any numbers

from 0 to 9 and any letters from A to Z; the
value of the rest three digits could only be
any number from 0 to 9. When the number
exceed 9999, capital letter from A to Z will
have to be used. A, B, C, D, E ... means
respectively 10000, 11000, 12000, 13000,
14000, 15000 .... For example: 10000 will
be written as A000; 11020 as B020, 12999
as C999.

21. Hydraulic Oil Temperature
Select “Hydraulic Oil Temperature” on the Sys-

tem Setup list and press F2 or Enter , and the
display moves to this page. Hydraulic Oil Temp
Operation
Hydraulic Oil Temp:
● Press F5 or ESC to return to the “System

Setup” page.
.
De al
pt
g no
XP2051203028
in ti
et a
n
rk er
Ma t
In

22. Lockout Information (Level 1)
This display indicates that the machine has

entered lockout state (level 1).
Lockout Information
Operation
● Press F5 to enter “System Unlock” page.

Macine model:
Machine No.:
Machine state: Lockout (1)
NOTE: Contact your local dealer to unlock the Current time:
machine when the system is locked.
.
System locked
De al
Contact manufacturer to unlock system
pt
g no
XP13041504
in ti
30. Lockout Information (Level 2)

et a
This display indicates that the machine has

n
entered lockout state (level 2).

rk er
Lockout Information
Operation
● Press F5 to enter “System Unlock” page. Macine model:

Ma t
Machine No.:
In
Machine state: Lockout (2)

NOTE: Contact your local dealer to unlock the Current time:
machine when the system is locked.
System locked
Contact manufacturer to unlock system
XP13041505

Et.
al
ep
DG
gA n
o
i
ti t
nP
na
ArNk er
eK
Ma t
BL In

SY195/205/215/225C9 Crawler Hydraulic Excavator Standard Values
Standard Values
.
5 Standard Values
De al
pt
5.1 Standard Values of Engine - related Parts............................................................... 5-3
5.2 Standard Values of Chassis-related Parts ............................................................... 5-4
g no
in ti
et a
n
rk er
Ma t
In

Standard Values SY195/205/215/225C9 Crawler Hydraulic Excavator
.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In
WARNING
jury or death.

5 STANDARD VALUES
5.1 Standard Values of Engine - related Parts
Std. value for

Item Measurement condition Unit Permissible value
new machine
High Idling rpm 2,060 ± 70 2,060 ± 70
Engine Speed Low Idling rpm 1,050 ± 50 1,050 ± 50
Rated Speed rpm 2,000 2,000
Intake Pres-
sure ● Air Cleaner Outlet Location kPa Min. 133 Min. 133
.
(Negative ● Arm-In Overflow+Max. rpm {mmH2O} {Min. 1,000} {Min. 1,000}
De al
Pressure)
pt
At Sudden Acceleration Bosch Max.25 35
Exhaust Color
g n
At High Idling
o
Index — —
Valve Clear- Intake Valve mm 0.25 0.152 ~ 0.381

in ti
ance Exhaust Valve mm 0.51 0.381 ~0.762
Compression ● Oil Temp: 40~60°C Mpa Min. 2.41 1.69
Pressure ● Engine Speed 250 rpm {kg/cm²} {Min. 24.6} {17.2}
et a
Blow-by Pres- ● Coolant Temp: Working Range kPa Max. 0.98 1.96
n
sure ● Arm-In Overflow: Max. rpm {mmH2O} {Max. 100} {200}

rk er
MPa Min. 0.29 0.25

High Idling
{kg/cm²} {Min. 3.0} {2.5}
Oil Pressure
MPa Min. 0.10 0.07
Low Idling
Ma t
{kg/cm²} {Min. 1.0} {0.7}

In
Oil Temp. ● Full Speed Range (In Oil Pan) °C 80 ~ 110 120
● Between fan belt pulley and
Fan Belt Ten- alternator belt pulley
mm 8.0 Min. 6, Max. 10
sion ● Deflection when pressed with
finger force of 58.8 N {6 kg}
● Between fan belt pulley and
A/C Compres-
compressor belt pulley
sor Belt Ten- mm 5~8 5 ~8
● Deflection when pressed with
sion
finger force of 58.8 N {6 kg}

5.2 Standard Values of Chassis-related Parts
Std. value for Permis-

Categ. Item Measurement condition Unit
new machine sible value
● Engine coolant temperature: Within
operational range
● Hydraulic oil temperature: Within
Engine Speed
2 pumps at relief operational range rpm 2,030 ± 50 2,030 ± 50

● Engine running at high idle
● Heavy-load operating mode (H)
● Arm-in relief condition
Speed when auto ● Engine running at high idle
.
De al
deceleration is oper- ● Auto idling switch on rpm 1,400 ± 50 1,400 ± 100
pt
ated ● All control levers neutral
UP mm 11.5 ± 0.5 11.5 ± 0.5
Boom control valve
g no
DOWN mm 9.5 ± 0.5 9.5 ± 0.5
Spool Stroke
IN mm 11.5 ± 0.5 11.5 ± 0.5

Arm control valve
● Engine stopped OUT mm 9.5 ± 0.5 9.5 ± 0.5
in ti
Bucket control valve ● See Control valve. DIG/DUMP mm 9.5 ± 0.5 9.5 ± 0.5
Swing control valve Travel (L&R) mm 9.5 ± 0.5 9.5 ± 0.5
et a
Forward &
Travel control valve mm 9.5 ± 0.5 9.5 ± 0.5
Reverse
n
Boom control lever mm 85 ± 10 85 ± 10

rk er
● Engine stopped
Arm control lever mm 85 ± 10 85 ± 10
● Control lever grip at center
Bucket control lever mm 85 ± 10 85 ± 10
● Max. reading at stroke end (except
Control Lever stroke
Ma t
Swing control lever mm 85 ± 10 85 ± 10

lever play in NEUTRAL position)
Travel control lever mm 115 ± 12 115 ± 12
In
● Engine stopped Work Equip-

mm Max. 15 Max. 20
● Slightly push the ment
control lever. Stop
Play of control lever pushing when re-
sistance is felt. Stroke mm Max. 20 Max. 25
● Max. reading at
stroke end.


Boom control Max. 19.6 Max. 24.5
Operating Force of Control Lever/
lever {Max. 2.0} {Max. 2.5}

Arm control Max. 19.6 Max. 24.5
lever ● Hydraulic oil temp: Within operational {Max. 2.0} {Max. 2.5}
Bucket con- range Max. 15.6 Max. 21.6
trol lever ● Engine running at high idle N {Max. 1.6} {Max. 2.2}
Pedal
Swing control ● Control lever grip at center {kgf} Max. 15.6 Max. 21.6
lever ● Pedal at tip {Max. 1.6} {Max. 2.2}
Travel control Max. 30.4 Max. 39.2
● Max. reading at stroke end
lever {Max. 3.1} {Max. 4.0}
Travel control Max. 93.1 Max. 107.8
.
De al
pedal {Max. 9.5} {Max. 11}
pt
● Hydraulic oil temp: Within operational
g n range
Unloaded ● Engine running at high idle 0~1.0 0~2.0
pressure ● Working mode: H {0~10} {0~20}
o
● All control levers in neutral position
in ti
● Hydraulic pump output pressure

Boom relief ● Hydraulic oil temp: Within operational 34.3 ± 1.0 33.3 ~ 35.3
range {350 ± 10} {340 ~ 360}
et a
● Operate corresponding control lever 34.8 ± 1.0 33.3 ~ 36.8

Arm relief
n
after engine runs at high idling speed. {355 ± 10} {340 ~ 375}
rk er
● Working mode: H
Hydraulic Pressure
34.8 ± 1.0 33.3 ~ 36.8

Bucket relief ● Hydraulic pump output pressure with {355 ± 10} {340 ~ 375}
all measurement circuits relieved MPa
Ma t
● Hydraulic oil temp: Within operational 25.5 ± 1.0 24.5 ~ 27.5

Swing relief {kg/cm²}
range {261 ± 10} {250 ~280}
In
● Operate corresponding control lever

after the engine runs at high idling
speed. 33.4 ± 1.0 32.4 ~ 34.4
Travel relief
● Working mode: H {342 ± 10} {330 ~ 351}
● Hydraulic pump output pressure with
all measurement circuits relieved
● Hydraulic oil temp: Within operational
range
Control circuit
● Engine running at high idle 3.9 ± 0.2 3.7 ~ 4.1
source pres-
● Self pressure reducing valve output {40 ± 2} {37 ~ 41}
sure
pressure with all control levers in
NEUTRAL position


● Hydraulic oil temp: Within operational range
Swing
● Working mode: H Deg. Max. 100 Max. 130
brake
● Swing circle misalignment amount when stopping mm (—) (—)
angle
after one turn
● For measuring posture see Swing 1.
● Hydraulic oil temp: Within operational range 90° sec. 3.1 ± 0.3 Max. 3.7
Time ● Engine running at high idle
taken ● Working mode: H
to start ● Time required for passing points 90°and 180° sec. 4.4 ± 0.4 Max. 5.5
.
De al
swing 180° from starting point
pt
g n
Swing
Time
o
● Working mode: H
taken to sec. 27 ± 3.5 Max. 30
in ti
● Time required for 5 turns after making initial 1

swing
turn
et a

n
● Engine stopped
rk er
● Keeping the upper structure transverse on a

Hydraulic
grade of 15°. For more information see Swing 2. mm 0 0
drift
● Notching a mating mark on inner and outer races
Ma t
of the swing circle

● Mating mark misalignment amount during 5 min.
In

Motor ● Engine running at high idle ml/
Max. 5 Max. 10
leakage ● Swing lockout switch: ON min
● Leakage amount for 1 minute during swing relief
● Hydraulic oil temp: Within operational range Lo 51.3 ± 5.1 46.2 - 60.4
Travel
● Working mode: H
Travel
speed
● Time required for track shoes to make 5 sec.
(unload- Hi 28.0 ± 1.4 26.6 - 31.4
turns after making one initial idle turn
ed)
● For more information on measuring posture
see Travel 1.


Cat. Item Measurement Condition Unit

Travel speed
● Engine running at high idle Lo 20 ± 2.5 17.5~22.5

(Actual run)
● Working mode: H
sec.
● Level ground
● Time required for traveling 10m after 10m trial run
Hi 13 ± 2.5 11.5~15.5

● Working mode: H
Deviation
.
● Travel Speed: Low
De al
mm Max. 800 Max. 900
● Hard level ground
pt
● Amount of deviation (χ) while traveling 20m after initial
Travel
10m trial run

g no
● For measuring posture see Travel 2/3.
Hydraulic drift
● Engine stopped
in ti
● Park the machine on a grade of 12°, with the sprocket

mm 0 0
in the downhill direction
● Measure the sliding distance for 5 minutes
et a
● For measuring posture see Travel 4.

n

travel motor
Leakage of

rk er
● Traveling with the sprocket locked mm 13.6 27.2

● Oil leakage amount for one minute with traveling in re-
lief condition
Ma t
In Bucket

tips
mm Max. 600 Max. 900

● Flat and level ground
● Bucket full of earth or with rated load (0.8m³: 1,440 kg)
cylinder
● Boom horizontal, arm fully retracted and bucket cylin-

Arm cylin- Boom
der fully extended mm Max. 20 Max. 27

Work Equipment
● Engine stopped
Hydraulic drift
● Work equipment control lever in neutral position

● Measure total amount of falling for 15 min. by measur-
der
mm Max. 20 Max. 20
ing the falling every 5 min. immediately after initial set-
ting
● Bucket tip lower distance
Bucket cylinder
● Boom cylinder: Cylinder retracting distance

● Arm cylinder: Cylinder extending distance mm Max. 45 Max. 45
● Bucket cylinder: Cylinder retracting distance
● For measuring posture see Work Equipment 1.


● Hydraulic oil temp: Within operation-
al range
Boom
● Working mode: H
UP sec. 3.4 ± 0.4 Max. 4.8
● Time required for the bucket to raise
from the ground to its stroke end
● For measuring posture see Work
Equipment 2.
● Hydraulic oil temp: Within operation- IN sec. 2.8 ± 0.4 Max. 4.5
al range
Work Equipment Speed
.
De al
Work Equipment
pt
● Working mode: H
Arm
g n ● Time required from dumping stroke OUT sec. 2.3± 0.3 Max. 3.5
end to digging stroke end
o
Equipment 3.
in ti
● Hydraulic oil temp: Within operation- DIG sec. 2.3 ± 0.4 Max. 3.4
al range
et a

n
Bucket
● Working mode: H
● Time required from dumping stroke
rk er
DUMP sec. 1.6 ± 0.3 Max. 2.3

end to digging stroke end
Ma t
Equipment 4.
In

Std. value for Judgement

Cat. Item Measurement condition Unit
new machine criteria

● Engine running at low idle
● Working mode: H
● Time required from maneuvering the joystick
Boom
to the moment that the bucket reaches the sec. Max. 1.0 Max. 1.2
ground and begins to push the machine up-
ward, within 50mm off the ground
● For measuring posture see Work Equipment
5.
.
De al
Time Delay
pt
● Working mode: H
● Average time required for operating the con-
Arm
sec. Max. 2.0 Max. 2.8

g n trol lever back and forth till the arm starts to
Work Equipment
move
o
in ti
6.

et a
● Working mode: H
n
Bucket
● Average time required for operating the con-

sec. Max. 1.0 Max. 3.6
trol lever back and forth till the arm starts to
rk er
move
7.
Ma t Cylinders
In
5 20
Internal Leakage

● Engine running at high idle ml/
Central Swivel
● Leakage amount for one minute with cylinder min

Joint
or travel measured at relief condition 10 50

work equipment and travel
Performance in Combined
simultaneous operation of
Amount of deviation in

Operations
● Working mode: H
● Travel Speed: Low mm Max. 200 Max. 220
● Amount of deviation measured for 20 m after
traveling about 10 m on a hard level ground
● For measuring posture see Travel 2.

Machine postures for measuring (For all models)
Control value: Spool stroke Travel 1: Travel speed (without load)
.
De al
pt
ZX215-1003002 ZX215-1003005
g n
Swing 1: Swing brake angle, time taken to
o
Travel 2: Travel speed (actual run), Travel de-
start swing, time taken to swing viation
in ti
45°
et a
n
rk er
Ma t
ZX215-1003003 ZX215-1003006
In
Swing 2: Hydraulic drift of swing Travel 3: Travel deviation
15°
x
10m
Sprocket
ZX215-1003004 ZX215-1003007

Travel 4: Hydraulic drift of Travel Work equipment 3: Arm speed
12°
ZX215-1003008 ZX215-1003011
.
De al
pt
Work equipment 1: Hydraulic drift of work Work equipment 4: Bucket speed
equipment g no
in ti
et a
n
rk er
ZX215-1003009 ZX215-1003012
Ma t
Work equipment 2: Boom speed Work equipment 5: Boom delay

In
ZX215-1003010 ZX215-1003013

Work equipment 6: Arm delay Work equipment 7: Bucket delay
ZX215-1003014 ZX215-1003015
.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

tE.
PAD nal
eGp
ng o
i
tKi t
a
AkNe rn
ar e
BLM Int

tE.
l
Pg Aona
DG
ep
in ti
etK a
n
ArkNer
Ma t
BL In

SY195/205/215/225C9 Crawler Hydraulic Excavator Testing and Adjusting
Testing and Adjusting
.
6 Testing and Adjusting
De al
pt
6.1 Engine Speed - Test and Calibrate .......................................................................... 6-3
6.1.1 Testing ........................................................................................................... 6-3
g n
6.1.2 Adjusting ........................................................................................................ 6-3
o
6.2 Exhaust Gas Color - Test ......................................................................................... 6-6
in ti
6.3 Valve Clearance - Adjust.......................................................................................... 6-8

6.3.1 Testing............................................................................................................ 6-8
6.3.2 Adjusting ...................................................................................................... 6-10
et a
6.4 Compression Pressure - Measure ..........................................................................6-11

n
6.5 Fuel Injection Timing - Test and Adjust .................................................................. 6-13

rk er
6.5.1 Testing.......................................................................................................... 6-13

6.5.2 Adjusting ...................................................................................................... 6-15
6.6 Engine Oil Pressure - Measure.............................................................................. 6-17
Ma t
6.7 Engine Speed Sensor - Adjust ............................................................................... 6-19

In
6.8 A/C Compressor Belt Tension - Test and Adjust ................................................... 6-20
6.8.1 Testing ......................................................................................................... 6-20
6.8.2 Adjusting ...................................................................................................... 6-20
6.9 Swing Bearing Clearance - Measure ..................................................................... 6-22
6.10 Track Tension - Test and Adjust ........................................................................... 6-24
6.10.1 Testing........................................................................................................ 6-24
6.10.2 Adjusting .................................................................................................... 6-25
6.11 Hydraulic Pressure in Hydraulic Circuits - Test and Adjust .................................. 6-26
6.11.1 Measuring .................................................................................................. 6-26
6.11.2 Adjusting..................................................................................................... 6-28
6.12 Control Circuit Oil Pressure - Test and Adjust...................................................... 6-30
6.12.1 Testing........................................................................................................ 6-30
6.12.2 Adjusting .................................................................................................... 6-31

Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator
6.13 Solenoid Valve Output Pressure - Measure......................................................... 6-32

6.14 Pilot Valve Output Pressure - Measure................................................................ 6-34
6.15 Pilot Valves (Work Equipment and Swing) - Adjust ............................................. 6-36
6.16 Work Equipment Hydraulic Drift - Test ................................................................. 6-37
6.17 Residual Pressure in Hydraulic Circuit - Release ................................................ 6-40
6.18 Oil Leakage - Measure ........................................................................................ 6-41
6.19 Air in Each Component - Bleed............................................................................ 6-46
.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In
WARNING
jury or death.

6 TESTING AND ADJUSTING
6.1 Engine Speed - Test and Calibrate
Engine speed calibrator
ID Part Number Part Name

1 B249900001206 Engine Speed Calibrator
6.1.1 Testing
Start the engine and keep the engine running
.
De al
until engine coolant temperature rises within
pt
the operational range. Key in the code on the
monitor and check if the engine speed is nor-
g n
mal in each throttle position.
o
Testing Items:
in ti
1. Engine speed at low idle
2. Engine speed at fuel control dial position

11 (H and S modes)
et a
3. Engine speed at relief, with fuel control dial

n
placed at position 11 (H and S modes)

rk er
4. Engine speed at auto idle

Ma t
6.1.2 Adjusting
In
Adjust the fixing point of the flexible shaft of

the throttle motor.
1. Connect the calibrator with the chassis ENG.

harness. Shaft bracket
2. Push the memory switch of the calibrator Tighten Lock nut
down to the OFF position. Loosen
3. Turn the start switch of the machine to the

ON position.
Min. throttle Max. throttle Flexible shaft
4. Start the engine. Check if engine speed is
within 1100±50 rpm range. (Throttle volt- WX215-1304008
age at speed level 1 is 1.3±0.03V)

5. Tighten the fixing position of the flexible

shaft when engine speed is lower than
1050 rpm; loosen the fixing position of the
flexible shaft when engine speed is higher
than 1150 rpm.
6. Shutdown the engine.
Speed calibration steps:
1. Connect the calibrator with the chassis

harness.
2. Push the memory switch of the calibrator

down to the OFF position. Turn the start Memory s/w
.
De al
switch of the machine to the ON position.
pt
MEMORY ON
3. Start the engine. Engine speed “XXXX” will H S L A/I
be displayed on the screen display of the

DOWN UP
g n
calibrator. Press the H button and hold it,
o
RPM
the screen will display “E. XXXX”. H S L A/I

in ti
4. When automatic speed calibration is com-

Analog output
A/I button
pleted, the screen display of the calibrator H button
will change from “E. XXXX” to “XXXX”. WX215-1304009

et a
5. Shut off the engine.

n
NOTE:
rk er
In order to make sure speed calibration is suc-

cessful, deactivate auto-idle mode after the
Ma t
calibration process and check the idling speed

at each speed level. If excessive variation is
In
found between the real speed and the target

speed, try automatic speed calibration once
again.

Engine speed reference (SY215C9)
Level Speed (rmp) Level Speed (rmp)

S1 1100 H1 1100
S2 1200 H2 1200
S3 1300 H3 1300
S4 1500 H4 1500
S5 1600 H5 1600
S6 1650 H6 1700
S7 1750 H7 1800
S8 1850 H8 1900
.
S9 1950 H9 2000
De al
S10 2050 H10 2100
pt
S11 2150
g n H11 2200
o
in ti
et a
n
rk er
Ma t
In

6.2 Exhaust Gas Color - Test
Testing tools
ID Model Part Name

1 YDJ-2006 Smoke meter
2 SV-2TY Opacimeter
CAUTION
● Do not touch any hot parts when mount-
ing or dismounting the testing tools.
.
De al
1. Measure with a smoke meter
pt
1) Put the filter paper into the smoke me-
g n
ter.
o
2) Insert the waste gas intake pipe into
the exhaust pipe.
in ti
3) Start the engine and keep the engine

running until engine coolant tempera-
et a
ture is within the operational range.

n
4) When engine speed increases sudden-

rk er
ly or is kept at high idle, direct exhaust

ZX215-1004002
gas through smoke meter to the filter
paper.
Ma t
5) Remove the filter paper from the smoke

In
meter. Read the smoke value through

the apparatus provided.
6) Remove the testing tools after measur-

ing. Make sure the machine goes back
to its normal state.

2. Measure with an opacimeter
1) Mount the opacimeter onto the exhaust

pipe by clamping it to the pipe outlet.
ZX215-1004003
.
De al
pt
2) Open the opacimeter and preheat it for
g n
about 15 minutes.
o
in ti
running until engine coolant tempera-

ture is within the operational range.
et a
n
rk er
ZX215-1004004
4) When engine speed increases sud-
denly or is kept at high idle, use the
Ma t
opacimeter to read the smoke value of

In
exhaust gas.
5) Remove the testing tools after measur-

ing. Make sure the machine goes back
to its normal state.

6.3 Valve Clearance - Adjust
Service Standard (Unit: mm)
Location Service Item Standard Value Limits Remedy

— Valve clearance (engine cold) 0.4 — Adjust
Special Tools
Symbol Tool Name and Shape Part Number Application
.
Flat head screwdriver
De al
pt
Valve clearance adjustment
MH060008
g n (Carried on vehicle)
o
in ti
Check and adjust valve clearance in cold state

as per the following procedure: Sight Glass
et a
6.3.1 Testing
n
1. Remove the rocker arm cover.

rk er
2. Turn the No.1 piston or the No.6 piston to

the top dead center of compression stroke
Ma t
by following the procedure below.

In
● Turn the engine until the mark 16 on

the flywheel aligns with the pointer on
sight glass of the flywheel shell.
Sight Glass
● Turn the No.1 piston or the No.6 piston
to the top dead center of compression
stroke.
16
Pointer
ZX215-1004009

NOTE:
When the rocker arm at the intake side and

rocker arm at the exhaust side cannot be
turned with hands, it is indicated that the pis-
ton has reached the top dead center of com-
pression stroke. Turning the engine by one
more turn, the top dead center of compression
stroke of No.1 piston and No.6 piston inter-
changes.
3. When the No.1 piston is at the top dead

center, adjust the valve clearance in a se-
.
quence marked by the black dot.
De al
pt
Cylinder 1 2 3 4 5 6
g n
INT ● ○ ● ○ ● ○
o
EXH ● ● ○ ● ○ ○
in ti
1) When a feeler gauge is used for such

measurement, resistance to a moving
et a
Valve clearance
feeler gauge in the clearance should be
n
felt.
rk er
2) If the feeler gauge moves easily in the

clearance, it is impossible to obtain ac-
curate result.
Ma t
4. If the measured value is out of specifica-

In
tion, readjustment shall be performed ac-

cording to the following method.
ZX215-1004007

6.3.2 Adjusting
1. To adjust valve clearance, loosen the lock-

Adjustment Screw
nut before adjusting the adjustment screw.
Standard clearance is achieved when re-
sistance to the feeler gauge is felt when Locknut
pulling it out from the clearance.
2. After adjustment, stop the turning motion

of the adjustment screw with a screwdriver,
and tighten the locknut.
Locknut: 16-24 N·m {1.7±2.5 kgf·m}
3. Go on with the next step until all valve
.
Valve Clearance
ZX215-1004006
De al
clearances marked with a black dot have
pt
been adjusted.
4. Check the clearances again with the feeler

g n
gauge. Readjustment should be made if
o
the value is out of specification.
in ti
5. When the engine is carried in vehicle, us-

ing to turn the adjustment screw will Adjustment
Screw
make your work easy.
et a
n
rk er
ZX215-1004008
Ma t
In

6.4 Compression Pressure - Measure
Service Standard

Each cylinder (at 200
2550kPa {26kgf/cm²} 1960 kPa {20kgf/cm²} Test
Compression rpm)
—
pressure Differential pressure
— Below 390 kPa {4kgf/cm²} Test
between cylinders
Special Tool
.
De al
Compression
pt
pressure gauge
connector
g n Measuring compression
MH061460
A pressure
o
M14×1.5
A
in ti
1. Reduction of compression pressure can be

an indication for engine overhaul.
et a
2. Check the compression pressure regularly

n
and pay attention to its variation from time

rk er
to time. In addition, in a new vehicle or

when new parts are installed for replace-
ment, the pressure may be higher due to
Ma t
running-in of the piston ring, valve seat,

etc. The pressure will become normal as
In
the parts wear.
3. Before testing, make sure engine oil, start

motor and battery are in normal condition.
4. Set the machine as per the following:
1) Preheat the engine until engine coolant

temperature reaches 75~85°C.
2) Switch off all lamps and auxiliary de-

vices.
3) Place the gear lever in a neutral posi-

tion.
5. Remove the entire fuel injector.

6. Cover the fuel injector mounting opening

with cloth.
Rags
7. Activate the start motor in order to run the
engine. Check if the cloth is stained by for- Injector
mounting hole
eign substances.
8. Determine the problem with the engine ac-

cording to the substances (engine oil and/
or coolant) on the cloth.
1) When engine oil is found, it might be

improper sealing caused by piston ring. ZX215-1004005
Check the piston ring.
.
De al
2) When engine oil and coolant are found,
pt
it might be cracking of cylinder. Replace
the crankcase.g n
9. Mount the gasket and tool to the fuel
CAUTION
o
injector mounting hole and fix them with
the injector cap. Install the compression When coolant and/or engine oil is found
in ti
pressure gauge. attached to the cloth, running the engine

may cause the hot coolant and engine oil
10. Start the engine and measure the com-
to squirt out through the mounting hole of
et a
pression pressure of each cylinder. Calcu-

the fuel injector. This is very dangerous.
late the differential pressure between the
n
Never touch or look into the fuel injector

cylinders.
mounting hole when the engine is running.
rk er
11. When the compression pressure and the

differential pressure between cylinders de-
viate from their limits, inject a small amount
Ma t
of engine oil through the fuel injector

In
mounting hole, and measure the compres-

sion pressure again.
● If the compression pressure is higher,

it is probably due to worn or damaged
piston ring or cylinder inner surface.
● If the compression pressure is still low,

it is probably due to stuck valve or im-
proper seating, or improperly mounted
gasket of cylinder head.

6.5 Fuel Injection Timing - Test and Adjust
Service Standard

— Fuel injection timing (BTDC) 14° — Adjust
Tightening Torque (Unit: N·m)
Symbol Parts Tightened Tightening Torque Remark

— Union nut 24 —
— Lock plate 3.4~4.9 —
— Lock seat - delivery valve 39~44 —
.
De al
— Nut (used for mounting fuel injection pump) 29~39 —
pt
Special Tool
g no
in ti
Universal Exten-
sion Rod
Testing and adjusting the
A MH061099
et a
fuel injection timing

14
n
A
rk er
6.5.1 Testing
Ma t
1. Remove the injection pipe, lock plate, lock

In
Injection pipe
seat, retainer ring and delivery valve from
the No.1 cylinder of the fuel injection pump. Lock Seat
Retainer Ring
2. After removal of all the parts, install the
Spring
lock seat. Lockplate
Delivery Valve
NOTE: The removed parts should be put
into light oil in order to keep them free from
dust.
ZX215-1004011

3. Install the prepared injection pipe onto

No.1 cylinder. Keep the other end of the in- Injection pipe
jection pipe downward so that fuel flowing

out can be observed.
4. Turn the crankshaft manually over 180° in

the forward direction to locate No.1 cylin-
der in a position that is about 30° from the
top dead center of compression stroke.
ZX215-1004012
.
De al
pt
5. The main pump is used to transfer fuel. As
the fuel flows out of the injection pipe, turn Injection pipe
g n
the engine manually in the forward direc-
o
tion.
in ti
NOTE: The engine positioning lever on the

governor must be placed in the starting
position.
et a
6. When the fuel coming out of the injection

n
pipe is about to stop, continue to turn the

engine slowly until the fuel stops coming
rk er
Priming pump Positioning Lever

out. ZX215-1004013
Ma t
7. Make sure that the flywheel mark and

In
pointer are one degree before the fuel in-

jection timing.
Pointer
ZX215-1004014

NOTE: When the fuel injection timing deviates

from its standard value, the following steps
must be followed for adjustment.
6.5.2 Adjusting
1. Loosen the mounting nuts of fuel injection

pump.
A: 4 nuts (on the flange)
B: 1 nut
.
De al
B
pt
g n A
o
ZX215-1004015
in ti
2. Targeted at the pointer, activate the injec-

et a
tion pump in order to adjust injection tim- Injection Pump

n
ing.
rk er
3. Tighten the nuts to specific torque. Mea-

sure the injection timing again.
Ma t
In
Pointer
ZX215-1004016

4. When the injection timing is slow, move the

injection pump toward the crankcase (di-
rection C). C
D
5. When the injection timing is fast, move the
injection pump away from the crankcase Injection Pump
(direction D).
ZX215-1004017
.
De al
6. When injection timing meets the standard
pt
value, install the delivery valve, spring, re-
Lock Seat
tainer ring, lock seat, lock plate and injec-
g n Injection pipe
tion pipe.
o
7. Tighten all the parts to specific torques.
in ti
Lockplate
et a
n
rk er
ZX215-1004018
Ma t
In

6.6 Engine Oil Pressure - Measure
Service Standard
Location Service Item Standard Value Limits

— Engine oil pressure at Min. speed, unloaded 145 KPa 49 KPa
— 70~90°C Max. speed, unloaded 295 KPa~490 KPa 195 KPa
Tightening Torque (Unit: N·m)
Symbol Part Tightened Tightening Torque Remark

— Engine oil pressure switch 7.8~12 Engine cold
.
Lubricant/Sealant
De al
pt
Symbol Location Part Number Amount
—
g no
Threads of pressure switch A420300000032 As necessary
1. Remove the engine oil pressure switch.

in ti
et a
n
Engine Oil
rk er
Pressure Switch
Ma t
In
ZX215-1004019
2. Mount the adaptor to where the engine oil

pressure switch has been removed. Mount Pressure Gauge
the engine oil pressure gauge to the adap-
tor.
Adaptor
ZX215-1004020

3. Preheat the engine until engine oil temper-

ature reaches 70-90°C.
4. Measure respectively the unloaded engine

oil pressure at minimum speed and maxi-
mum speed.
5. If the measured value is lower than the

specified standard value, check the entire
lubrication system.
6. After measuring, apply sealant to the

threads of pressure switch. Tighten the
pressure switch to specific torque.
.
De al
pt
NOTICE
Then engine oil pressure switch must be
g n
installed when the engine is cold.
o
in ti
et a
n
rk er
Ma t
In

6.7 Engine Speed Sensor - Adjust
NOTE: Remove the engine speed sensor (1)

before adjusting. Check for presence of metal
chips and for damaged sensor top. Restore
the sensor.
.
De al
ZXT215-1004001
pt
1. Screw on the sensor (1) until its end con-
g n
tacts with ring gear tip (2) of the flywheel. 1 2
o
2. Unscrew the sensor some degrees.
in ti
Degrees: 1.2~1.4 turns
Adjust the clearance (a) between the

et a
sensor end and the flywheel edge to 2±0.2

n
mm.
3
rk er
3. Tighten the sensor (1) with the nut (3). a

ZX215-1004021
Nut: 49.0~68.6 N·m {5~7kg·m}
Ma t
4. Make sure that the engine speed is dis-

played properly on the control panel after
In
adjustment.

6.8 A/C Compressor Belt Tension - Test and Adjust
6.8.1 Testing
Press the intermediate point of the belt be-

Compressor Belt
tween the drive pulley and the compressor pul- Pulley
ley with a finger force of about 58.8 N(6kgf),
and measure deflection (A) of the belt, which A
shall be 5~8 mm (0.20 in~0.31in).
.
De al
Drive Pulley
pt
ZX215-1004022
6.8.2 Adjusting
g no
NOTE: If the belt deflection is abnormal, adjust
in ti
it according to the following procedure.
4
1. Loosen the bolts (1) and (2). 1
et a
2. Move the compressor (3) and the bracket

(4) together to adjust belt tension.
n
3. After positioning the compressor (3), tight-

rk er
en the bolts (1) and (2). 2
4. Check belt tension again after adjustment. 3

Ma t
In
ZXT215-1004002

Reference
Use a tensiometer to check the compressor

belt tension.
New Belt Used Belt

637±108 N 441±88.2 N
{65±11 kgf} {45±9 kgf}
NOTE:
● Check each belt for damage. Check the

V-groove and the V-belt for wear. In addi-
.
tion, it is especially important to keep the
De al
V-belt free from friction with bottom of the
pt
V-groove. g n
● Contact local Sany dealer and replace the
belt in case of the following conditions.
o
● The fan belt has been stretched and
in ti
little margin is left for adjustment.
● Cuts or cracks are found in the belt.

et a
● Abnormal sliding or noise.

n
● When a new belt is mounted, readjust the

rk er
belt tension after one hour operation.

Ma t
In

6.9 Swing Bearing Clearance - Measure
Measuring tool
Symbol Part Number Part Name

H 60033930 Dial gauge
● The following steps are to be followed

when measuring the clearance of swing
bearing.
CAUTION
.
De al
● Park your machine on a level ground.
pt
Lower your work equipment to the
ground. g n
● Do not put your hands or feet under the
o
undercarriage during measurement.
in ti
1. Fix the dial gauge (H) to the track frame

and apply the probe to the lower end of the
outer race.
et a
n
2. Place the work equipment to the maxi-

mum reach position. Raise the bucket to
rk er
a height that the bucket tips and the swivel

table bottom are on the same level.
H
Ma t
At the moment, the front of upper structure

lowers while the rear rises.
In
ZX215-1004023
3. Set the dial gauge (H) to zero.
4. Set the arm almost perpendicular to the

ground and lower the boom until the front
track shoe floats.
At the moment, the front of upper structure

rises while the rear lowers.
5. Read the dial gauge (H).
6. Restore the machine to the condition of
ZX215-1004024

step 2. Check the dial gauge (H) to see if it

reads zero.
The value indicated by the dial gauge (H)
is the clearance of the bearing.
150～200mm
For more information, see “Swing bearing”
on page 4-13.
ZX215-1004025
Repeat step 3 through step 5 if the dial
gauge (H) reads a value other than zero.
.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

6.10 Track Tension - Test and Adjust
6.10.1 Testing
1. Move your machine forward for a distance

that is equal to the length of track on the
ground. Keep running the engine at low 3 2
idle. Park your machine slowly. a
2. Place a straight bar on the track over idler

(1) and carrier roller (2).
NOTE: A straight angle steel bar is recom-

mended for this purpose as it has good
.
1
De al
resistance to bending strain.
pt
ZX215-1004026
3. Measure the maximum clearance (a) be-
tween the upper surface of track and the
g n
lower edge of the straight bar.
o
● Max. clearance (a): 10~30 mm (0.4~1.2
in ti
in)
et a
n
rk er
Ma t
In

6.10.2 Adjusting
● If track tension is incorrect, make adjust-

ment as per the following instruction.
CAUTION
● Do not loosen the valve over one turn.
If the valve is loosened too much, the
grease under high pressure may cause
the valve to eject.
1. Reduce track tension
.
De al
1) Loosen the valve (1) to discharge
pt
grease. Tighten the valve after dis-
charging.
g n
2) Check the track tension again as per
o
1
the above method after adjustment.
in ti
2. Increase track tension

2
1) Add grease through the grease fitting
et a
(2) with a grease gun. ZXT215-1004003

n
2) Check the track tension again as per

rk er
the above method after adjustment.

Ma t
NOTE: Add grease until the gap (b) be-

tween the idler guide and the track frame
In
end becomes zero. If the tension is till low,

it indicates that the pins and bushings are
seriously worn. Replace the pins and bush-
ings, or remove a piece of track shoe.
ZX215-1004027

6.11 Hydraulic Pressure in Hydraulic Circuits - Test and Adjust
Testing and adjusting tools

60038932 Hydraulic Tester
—
B210770000084 Adaptor
NOTE: The hydraulic pressure in work equip-

ment, swing and travel (hydraulic pump out-
put) circuits can be viewed on the monitor.
6.11.1 Measuring
.
De al
pt
CAUTION
g n
● Lower the work equipment to the
o
ground and stop the engine. Operate
the control levers for several times to
in ti
release the residual pressure in hydrau-

lic circuits.
et a
● Open the butterfly nut on the breather

valve and press the relief button to re-
n
lease pressure in the hydraulic tank.

rk er
1. Preparatory work before measuring
1) Remove the plug (1) and plug (2) for

Ma t
measuring the hydraulic pressure.

In
● Plug (1): For oil circuit of rear pump

2
● Plug (2): For oil circuit of front pump 1
2) Install the priming adaptor and connect

it to the hydraulic tester.
● Use an oil pressure gauge with a ca-

pacity of 40 MPa {408 kgf/cm²}. ZX215-1004028
3) Start the engine and keep it running

until the hydraulic pressure rises to a
point within the operational range.

2. Measurement of unloading pressure
1) Start the engine.
2) Measure the hydraulic pressure when

the engine is running at high idle and
all control levers are in a neutral posi-
tion.
NOTE: The hydraulic pressure indicat-

ed is the pressure when the unloading
valve unloads.
.
3. Measurement of work equipment pres-
De al
sure at relief
pt
1) Start the engine and move the cylinder
g n
to be measured to its stroke end.
o
in ti
the cylinder is in relief condition.

et a
ed is the pressure when the main relief

n
valve is in relief condition.

rk er
4. Measurement of swing pressure at relief

Ma t
1) Start the engine. Reach out the work

In
equipment as far as possible. Lower

the work equipment on the ground in
order to restrict swinging.

the swing circuit is in relief condition.
NOTE: The hydraulic pressure indi-

cated is the pressure when the swing
motor relief valve is in relief condition.
NOTE: The relief pressure of swing

motor is lower than the main relief pres-
sure.

5. Measurement of travel pressure at relief
1) Start the engine and lock the travel

mechanism.
NOTE: Place the pin (1) between the

sprocket and the track frame to lock the
travel mechanism.

the travel circuit is in relief condition. 1

ed is the pressure when the main relief
.
ZXT215-1004004
De al
valve is in relief condition. When the
pt
travel circuit is in relief condition, the
pressure indicated is always the pres-
g n
sure at high relief.
o
in ti
6.11.2 Adjusting
NOTE: The boom relief valve cannot be ad-

justed.
et a
n
1. Adjustment of main relief pressure

rk er
NOTE: If the high relief pressure is abnor-

mal, adjust the high pressure setting of the 3
main relief valve (3) as per the following.
Ma t
1) Disconnect the pilot hose.

In
2) Loosen the locknut (4). Turn the adjust- ZXT225-1104002

ment screw (5) to adjust the pressure.
Pressure rises as the screw turns right.

Pressure drops as the screw turns left.
Each turn of the screw equals about: 4

12.5 MPa {128 kgf/cm²}
Locknut:
53.5±4.9 N·m {5.5±0.5 kgf·m}
5
ZX215-1004029

3) Check the pressure again after adjust-

ment. Measure the pressure according
to the procedure described above.
● Connect the pilot hose before measur-

ing the pressure.
● Adjustment of the high pressure setting

side will affect the low pressure setting
side. The low pressure setting side is,
therefore, to be adjusted too.
.
2. Adjustment of swing relief pressure
De al
pt
NOTE: If the swing relief pressure is ab-
normal, adjust the swing motor relief valve
g n
(6) as per the following.
o
1) Loosen the locknut (7). Turn the adjust-
in ti
ment screw (8) to adjust the pressure.
Pressure rises as the screw turns right.

et a
Pressure drops as the screw turns left.

n
Each turn of the screw equals about:

rk er
6.71 MPa { 68.4 kgf/cm²}
Locknut:
8
6 7
Ma t
78-103 N·m{8.0-10.5 kgf·m}

ZXT225-1104003
In
2) Check the pressure again after adjust-

ment. Measure the pressure according
to the procedure described above.
ZX215-1004030

6.12 Control Circuit Oil Pressure - Test and Adjust
Testing and adjusting tools

—
B210770000084 Adaptor
6.12.1 Testing
CAUTION
.
De al
pt
g n
o
lic circuits.
in ti
et a
1. Remove the plug (1) for measuring the hy-

n
draulic pressure.
rk er
2. Install the priming adaptor and connect it

to the hydraulic tester.
Ma t
Use an oil pressure gauge with a capacity

In
of 6 MPa{61 kgf/cm²}
3. Start the engine and keep it running until

1
the hydraulic pressure rises to a point with-
in the operational range.
4. Measure oil pressure when the engine is 2

running at high idle and all control levers
are in a neutral position. ZXT215-1004007

6.12.2 Adjusting
1. If the measurement is less than 3.5 kgf/

cm², loosen the retaining nut (2) and screw
in adjusting stud (3). Watch the change 3 2
of readings on the pressure gauge at the
same time. Tighten the retaining nut (2)
when proper pressure value is achieved.
2. Remove all the tools after measurement

and make sure the machine returns to its
normal condition.
.
ZX215-1004031
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6.13 Solenoid Valve Output Pressure - Measure
Measuring tools

—
B210770000084 Adaptor
NOTE: Make sure that the initial pressure of

control oil circuit is normal before measuring
the output pressure of solenoid valve.
.
CAUTION
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o
lic circuits.
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1. Disconnect the hose of solenoid valve to

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measure the pressure at the outlet.
No. Solenoid Valves to be Measured 5 4 3 2 1

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1 Solenoid valve - high/low travel speed

In
2 Solenoid valve - swing priority

Solenoid valve - bucket confluence/difflu-
3
ence
4 Solenoid valve - boom priority A
5 Solenoid valve - pilot lockout
2. Install a tee to location (A) on each sole-

noid valve and connect the hose.
WXT215-1206001G
3. Mount the adaptor onto the tee and con-
nect it to the hydraulic tester.
Use a hydraulic tester with a capacity of 6

MPa{61 kgf/cm²} .

4. Start the engine and keep it running un-

til the hydraulic oil temperature rises to a
5. Run the engine at full speed. Operate the

control levers to open or close each sole-
noid valve, and measure the pressure.
● The function of each solenoid valve

can be checked through the monitor's
monitoring function. (This is a special
function of the monitor.)
● When each output pressure reads the

following values, the solenoid valve is
.
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normal.
pt
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High speed travel
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Solenoid Valve Output Pressure
in ti
OFF (de-energize) 0 {0}

ON (energize) 3.9~4.1 MPa{39~41 kgf/cm²}
et a
Swing priority
n
Solenoid Valve Output Pressure

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OFF (de-energize) 0 {0}

ON (energize) 3.0~3.9 MPa{30~39 kgf/cm²}
Ma t
6. Remove all measuring tools after measure-

ment. Make sure that the machine returns
In
to its normal condition.
Table of functioning state - pilot lock solenoid

valve
Functioning State Function

Lock OFF
Lockout control
Free ON

6.14 Pilot Valve Output Pressure - Measure
Measuring tools

—
B210770000084 Adaptor
NOTE: Make sure that the initial pressure of

control oil circuit is normal before measuring
the output pressure of pilot valve.
.
1. Remove the pilot pressure switch.
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Oil Circuit Oil Circuit
No. No.
Measured
g n Measured
1 Travel left 7 Bucket DUMP
o
2 Travel right 8 Arm IN
in ti
3 Arm OUT 9 Swing

4 Bucket DIG
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5 Boom DOWN
6 Boom UP 2 1
n
5 4 3
6
2. Install the adaptor and connect it to the hy- 8 7
rk er
9
draulic tester. ZXT225-1104005
Use a hydraulic tester with a capacity of 6

Ma t
MPa {61kgf/cm²}
In
3. Start the engine and keep it running un-

til the hydraulic oil temperature rises to a
4. Measure the output pressure when the en-

gine is running at high idle and all control
levers of the tested circuit are in neutral
position or at full stroke.

NOTE: When the measured output pres-

sure reads the following values, the pilot
valve is normal.
Control Lever Hydraulic Pressure

Neutral 0{0}
Close to the average initial pres-
Full stroke sure of oil control circuit
(See Table of Standard Values)
5. Remove all measuring tools after measure-

ment. Make sure that the machine returns
to its normal condition.
.
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6.15 Pilot Valves (Work Equipment and Swing) - Adjust
● If the play of work equipment or swing con-

trol lever is excessive, make adjustment as
per the following procedure.
1. Remove the work equipment and swing pi-

lot valve assembly.
2. Remove the rubber sleeve (1).

2
3. Loosen the locknut (2). Screw on the disc
3
(3) until it contacts with the four heads of
plunger (4). 1
.
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NOTE: Do not move the plunger.
pt
4. When the disc (3) is fixed, tighten the lock-
g n 4
nut (2) to specified torque.

o
Locknut:
in ti
98~127 N·m {10~13 kgf·m} ZX215-1004032
5. Install the rubber sleeve (1).

et a
6. Install the work equipment and swing pilot

valve assembly.
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6.16 Work Equipment Hydraulic Drift - Test
NOTE: If hydraulic drift exists in the work

equipment cylinder, check it according to the
following procedure and determine whether
the failure lies in the cylinder seal or in the
control valve.
1. Boom and bucket cylinders
1) Park your machine in an attitude as

shown and stop the engine.
NOTE: Load the bucket fully with earth
.
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or impose rated load on the bucket.
pt
2) Operate the control levers so that the
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boom is in the raising position and the ZX215-1004033

bucket in the digging position.
● If the lowering speed rises, the prob-

et a
lem lies in the cylinder seal. If nothing

n
changes, the problem lies in the control

valve.
rk er
● Operate the control levers with engine

start switch in the ON position.
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● If the pressure in accumulator drops,

In
charge the accumulator again by run-

ning the engine for about 10 seconds.
2. Arm cylinder

1) Park your machine in an attitude as

shown. The distance between the arm
cylinder and the digging stroke end is
100 mm. Stop the engine.
2) Operate the control levers in order to

place the arm in the digging position.
● If the lowering speed rises, it is failure

of the cylinder seal. If nothing changes,
it is failure of the control valve.
ZX215-1004034
.
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[Reference]
o
If hydraulic drift is caused by failure of the
in ti
cylinder seal, the reason for lowering speed

increase during the above operation is de-
scribed below:
et a
1) If the machine is set in the above position

n
(where the holding pressure is applied to

the bottom side), the oil leaks from the bot-
rk er
tom side to the head side. The pressure in

the head side is increased.
Ma t
2) As the pressure in the head side de-

creases, the pressure in the bottom side
In
increases in order to keep it balanced.

This process is repeated until balance is
reached at a certain level depending on
the amount of leakage.
3) When the pressure is balanced, the lower-

ing speed decreases. If the control levers
are operated according to the above proce-
dure, the oil circuit in the head side opens
to the drain circuit (while the bottom side is

closed by a check valve), and the oil flows

to the drain circuit from the head side. As a
result, the lowering speed increases.
3. Checking the pilot valve
While the pressure in the accumulator is

high, set the hydraulic lockout control in
the LOCKED/FREE position and measure
the hydraulic drift respectively.

.
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pt
● If there is a difference in hydraulic drift

g n
between the LOCKED position and the
o
FREE position, it the failure (internal
fault) of the pilot valve.
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6.17 Residual Pressure in Hydraulic Circuit - Release
CAUTION
● Release the residual pressure in the hy-
draulic circuit before disconnecting the
lines between the hydraulic cylinders
or between the hydraulic motor and the
control valve.
NOTE: Even if the swing motor circuit and

the travel motor circuit are free from re-
sidual pressure, they will be influenced by
.
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the internal pressure of hydraulic tank. The
pt
breather valve must therefore be opened
to release pressure prior to such operation.
g n
1. Stop the engine, loosen the butterfly nut on
o
the breather valve, and press the release
in ti
button to release the pressure in hydraulic
tank.
2. Turn the engine start switch to the ON

et a
position and operate the control levers for

n
several times.
rk er
● The pilot lock valve must be energized.

Operate the control levers with the en-
gine start switch in the ON position.
Ma t
● The pressure in accumulator will be

In
released after the control levers have

been operated 2 or 3 times.
3. Start the engine and keep the engine run-

ning at low idle for about 10 seconds in
order to increase the pressure in accumu-
lator. Stop the engine.
4. Repeat the above step 2 through step 3

several times.

6.18 Oil Leakage - Measure
1. Measure oil leakage from boom cylinder
1) Start the engine and keep it running un-

til the hydraulic oil temperature is within 1
the operational range. Fully extend the
boom cylinder.
NOTE: Release the residual pressure

in the circuits.
See “Residual Pressure in Hydraulic

Circuit - Release” on page 6-40.
.
De al
2) Disconnect the hose (1) on the cylinder
pt
ZXT215-1004010
head side and plug the hose end with a
cap.
g n
NOTE: Be careful not to disconnect the
o
hose on the cylinder bottom side.
in ti
3) Start the engine and apply relief pres-

sure to the bottom side of the cylinder
while the engine is running at high idle.
et a
4) Hold this condition for 30 seconds.

n
Measure oil leakage for one minute.

rk er
5) Make sure that the machine returns to

its normal condition after measurement.
Ma t
In

2. Measure oil leakage from arm cylinder
1) Start the engine and keep it running un- 2

til the hydraulic oil temperature is within
arm cylinder.

in the circuits.

ZXT225-1104007
.
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cap.
pt
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3. Measure oil leakage from bucket cylin-

der
1) Start the engine and keep it running un-

til the hydraulic oil temperature is within
bucket cylinder.

in the circuits.

.
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3
pt
cap.

g n
o
3) Start the engine and apply relief pres- ZXT225-1104008
in ti


et a

n

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4. Measure oil leakage from swing motor
1) Fully extend the work equipment. Lower

the bucket on the ground and raise the
machine slightly. Secure machine from
rotating clockwise or counter clockwise
while testing. Stop the engine.
2) Disconnect the hose (4) and the hose

(5). Plug the hose ends with caps.

sure to the bottom side of the swing 5
motor while the engine is running at
4
high idle. Measure oil leakage under
.
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this condition.
pt
● Hold the condition described in step 3)
g n
for 30 seconds. Measure oil leakage for
one minute.
o
ZXT225-1104006
● After the first measurement, turn the

in ti
upper structure 180°and measure the

leakage again in the same way.
et a

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5. Measure oil leakage from travel motor
1) Remove the cover of the travel motor.
2) Start the engine and lock the travel

mechanism.
NOTE: Insert pin (1) between the

sprocket and the track frame to lock the
travel mechanism.
.
ZXT215-1004004
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pt
3) Disconnect the drain hose (6) of the
g n
travel motor. Plug the hose end with a
o
cap.
in ti

sure to the bottom side of the travel
motor while the engine is running at
et a
high idle. Measure oil leakage under

this condition.
n
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6
WARNING
ZXT215-1004014
● During measurement, mis-operation of
Ma t
the control levers can cause serious ac-

cidents. Make sure that all signals are
In
given correctly.
● Hold the condition described in step 4)

for 30 seconds. Measure oil leakage for
one minute.
● Rotate the motor slightly. Change the

positions of the valve plate and the
travel motor and of the cylinder and pis-
ton. Repeat the measurement several
times.


6.19 Air in Each Component - Bleed
Air bleeding procedures

Air bleeding item
1 2 3 4 5 6
Bleed air Bleed Bleed air Bleed air
Contents of work Starting Starting
from hydrau- air from from swing form travel
engine operation
lic pump cylinder motor motor
● Replacing hydraulic oil

○ ○ ○ ○ ○ ○
● Cleaning filter element
(Note) (Note)
● Replacing return filter element ○ ○
● Repairing/replacing hydraulic pump
○ ○ ○ ○
.
● Removing suction piping
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● Repairing/replacing control valve ○ ○ ○
pt
● Replacing cylinder
○ ○ ○
● Removing cylinder piping
g n
● Replacing swing motor
○ ○ ○
o
● Removing swing motor piping
● Replacing travel motor
in ti
○ ○ ○
● Removing travel motor piping
et a
NOTE: Bleed air from the swing motor and

travel motor only when the oil in the motor
n
cases is drained.
rk er
1. Bleed air from hydraulic pump

Ma t
1) Loosen the air bleeder (1) and check

that oil oozes out through the air bleed-
In
er.
1
2) Tighten the air bleeder (1) if oil is seen.
Bleeder:
7.8~9.8 N·m{0.8~1.0 kgf·m}
NOTE: Run the engine at low idle for

10 minutes after bleeding the air ac-
cording to the above procedure.
ZXT215-1004015

2. Bleed air from hydraulic cylinder

running at low idle for 5 minutes.
2) Raise or lower the boom 4 or 5 times

with the engine running at low idle.
NOTE: Be careful not to apply relief

pressure. Stop the piston when the rod
is about 100 mm before stroke end.
3) Repeat step 2) with the engine running

at high idle.
.
4) While running the engine at low idle,
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move the piston rod to the stroke end
pt
and apply relief pressure.
g n
5) Bleed air from arm cylinder and bucket
cylinder by performing step 2) through
o
step 4).
in ti
NOTE: When a new cylinder is in-

stalled for replacement, bleed the air
from the new cylinder before mounting
et a
it to the work equipment. Especially the

n
boom cylinder, once mounted to the

work equipment, its piston rod is un-
rk er
able to reach its stroke end in lowering

operation. Therefore, the air must be
bled from the boom cylinder before it is
Ma t
mounted to the work equipment.

In
3. Bleed air from swing motor
1) Start the engine and run the engine at

low idle.
2) Bleed air from the swing motor by turn-

ing the upper structure slowly.

4. Bleed air from travel motor
1) Start the engine and run the engine at

low idle.
2) Loosen the bleeder (2) and check that

oil oozes out through the air bleeder.
3) Tighten the air bleeder (2) if oil is seen.
Bleeder:
27.5~35.3 N·m{2.8~3.6 kgf·m}

2
ZXT215-1004016
.
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Table of monitored items
Monitored Item Unit Remark
Controller Mode Selection Graph

High/Low Travel Speed Selection Graph
Auto Idle Selection Graph
Engine Speed r / min
Pressure - Front pump Kg
Pressure - Rear pump Kg
Current - Proportional Valve (Solenoid, Front pump) mA
.
Current - Proportional Valve (Solenoid, Rear pump) mA
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pt
Pilot Pressure - Boom Raise Kg
Pilot Pressure - Boom Lower Kg
g n
Pilot Pressure - Arm In Kg
o
Pilot Pressure - Arm Out Kg
in ti
Pilot Pressure - Bucket Curl Kg

Pilot Pressure - Bucket Dump Kg
et a
Pilot Pressure - Swing Kg

n
Pilot Pressure - Travel Left Kg

rk er
Pilot Pressure - Travel Right Kg

Bucket Confluence ON / OFF
Solenoid
Ma t
Swing Priority ON / OFF

Valve 1
In
Hi/Lo Speed Switching ON / OFF

Voltage - Fuel Control Dial V
Voltage - Motor Position V
Temperature - Engine Coolant °C Gauge reading
Temperature - Hydraulic oil °C Gauge reading
Pressure - Engine Oil KPa

tE.
l
Pg Aona
DG
ep
in ti
etK a
n
ArkNer
Ma t
BL In

SY195/205/215/225C9 Crawler Hydraulic Excavator Troubleshooting
Troubleshooting
.
7 Troubleshooting
De al
pt
7.1 Points to Remember When Troubleshooting ........................................................... 7-3
7.2 Troubleshooting Procedures .................................................................................... 7-5
g n
7.3 Connector Location and Electrical Circuit Diagram ................................................. 7-8
o
7.3.1 Connector location layout ............................................................................ 7-12
in ti
7.3.2 Electrical element circuit diagram (cab circuit)............................................. 7-18

7.3.3 Electrical control circuit diagram (engine circuit).......................................... 7-20
7.3.4 Electrical control circuit diagram (sensor and solenoid valve circuit) ........... 7-22
et a
7.3.5 SWP type connector .................................................................................... 7-23

n
7.3.6 A/AMP type connector ................................................................................. 7-24

rk er
7.3.7 DT type connector ....................................................................................... 7-25

7.4 Failure Symptoms and Troubleshooting Codes ..................................................... 7-26
7.5 Troubleshooting with an Event Code ..................................................................... 7-28
Ma t
7.6 Troubleshooting of Electrical System (E - Mode)................................................... 7-63

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7.7 Troubleshooting of Hydraulic and Mechanical Systems (H - Mode) ...................... 7-93

Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator
.
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WARNING
jury or death.

7 TROUBLESHOOTING
7.1 Points to Remember When Troubleshooting
● Stop the machine in a level ground, and check that lock pins, blocks, and parking brake are
securely fitted.
● When carrying out the operation with two or more workers, keep strictly to the agreed signals,
and do not allow any unauthorized person to come near.
● If the radiator cap is removed when the engine is hot. Hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
.
● Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
De al
pt
● When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
g n
● When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to
o
connect it properly.
in ti
The aim of troubleshooting is to pinpoint the It will also cause a waste of man-hours,
basic cause of the failure, to carry out repairs parts, or oil or grease, and at the same
et a
swiftly, and to prevent reoccurrence of the fail- time, will also lose the confidence of the
n
ure. user or operator.

rk er
When carrying out troubleshooting, important For this reason, when carrying out
point is to understand the structure and func- troubleshooting, it is necessary to carry out
tion. thorough prior investigation and to carry
Ma t
out troubleshooting in accordance with the

However, a short cut to effective troubleshoot- fixed procedure.
In
ing is to ask the operator various questions

to form some idea of possible causes of the 2. Points to ask user or operator:
failure that would produce the reported symp-
1) Have any other problems occurred apart
toms.
from the problem that has been reported?
1. When carrying out troubleshooting, do not
2) Was there anything strange about the
hurry to disassemble the components.
machine before the failure occurred?
If components are disassembled immedi-
3) Did the failure occur suddenly, or were
ately any failure occurs:
there problems with the machine condition
● Parts that have no connection with the before this?
failure or other unnecessary parts will
4) Under what conditions did the failure oc-
be disassembled.
cur?
● It will become impossible to find the
5) Had any repairs been carried out before
cause of the failure.

the failure? When were these repairs car- 5. Troubleshooting

ried out?
● Use the results of the investigation and
6) Has the same kind of failure occurred be- inspection in Items 2 – 4 to narrow down
fore? the causes of failure, then use the trouble-
shooting flowchart to locate the position of
3. Check before troubleshooting the failure exactly.
1) Check the oil level. ● The basic procedure for troubleshooting is
2) Check for any external leakage of oil from as follows.
the piping or hydraulic equipment. 1) Start from the simple points.
3) Check the travel of the control levers. 2) Start from the most likely points.
4) Check the stroke of the control valve spool.
.
3) Investigate other related parts or informa-
De al
5) Other maintenance items can be checked tion.
pt
externally, so check any item that is con- 6. Measures to remove root cause of failure
sidered to be necessary.
g n
● Even if the failure is repaired, if the root
4. Confirming failure
o
cause of the failure is not repaired, the
same failure will occur again. To prevent
in ti
● Confirm the extent of the failure yourself,
and judge whether to handle it as a real this, always investigate why the problem
failure or as a problem with the method of occurred. Then, remove the root cause.
et a
operation, etc.
n
NOTE: When operating the machine to

reenact the troubleshooting symptoms, do
rk er
not carry out any investigation or measure-

ment that may make the problem worse.
Ma t
In

7.2 Troubleshooting Procedures
If some phenomenon occurs on a machine that looks like a failure, identify the corresponding
troubleshooting No. and proceed to the explanations for diagnosis.
Follow six steps listed below to diagnose and analyze for troubleshooting, and find the causes
and work out the corresponding methods.
1. Read related technical manuals in detail. d. What kind of trouble did machine have
Have a knowledge of related system, before?
principle of operation, and structure,
function and technical specification of For example: Which parts have been
repaired or replaced?
.
parts.
De al
e. What has been done after troubles take
pt
2. Ask operator
place and how about the reaction?
Before checking, ask related person, i.e.
g n
the operator for all information about the
f. Will the trouble reoccur? Does the trou-
ble occur regularly?
o
failure.
in ti
3. Check before starting
a. Current working condition of machine
(Whether machine is operated prop- Before starting troubleshooting, check
erly). the operator's records on operation,
et a
maintenance and service of the machine.

b. When troubles are found and what kind
Understand whether related personnel has
n
of operation does machine perform at

done wrong in operation, maintenance and
that time?
rk er
service. Check for wrong operation and

c. Development of troubles (Whether maintenance at the same time.
troubles are becoming severer or occur
Ma t
for the first time.)

In

Item Criterion Remedy
1. Check fuel level and type of fuel — Add fuel

2. Check for impurities in fuel — Clean, drain
Lubricating oil, coolant
3. Check hydraulic oil level — Add oil

4. Check hydraulic oil strainer — Clean, drain
5. Check swing drive oil level — Add oil
6. Check engine oil level (in oil pan) — Add oil
7. Check coolant level — Add water
8. Check dust indicator for clogging — Clean or replace
9. Check hydraulic filter — Replace
10. Check final drive oil level — Add oil
.
De al
—
mechanical Electrical equipment
pt
1. Check for looseness, corrosion of battery terminal and
— Tighten or replace
wiring
—
g n
2. Check for looseness, corrosion of alternator terminal
Tighten or replace
and wiring
o
3. Check for looseness, corrosion of start motor terminal
Tighten or replace
in ti
and wiring
equipment
Hydraulic,
1. Check for abnormal noise and smell — Repair

et a
2. Check for oil leakage — Repair

3. Bleeding air — Bleed air
n
1. Check battery voltage (with engine stopped) 20-30V Replace

rk er
Electrics, electrical equipment
2. Check electrolyte level — Add or replace

3. Check for discolored, burnt, exposed wiring — Replace
4. Check for missing wiring clips and hanging wiring — Repair
Ma t
5. Check for wet wires (esp. wet connectors or terminals) — Disconnect con-
In
6. Check for blown or corroded fuses nector and dry

7. Check alternator voltage (with engine speed at middle —
or higher) After running for Replace
8. Check operating sound of battery relay (when start several minutes: Replace
switch is turned ON or OFF) 27.5~ 29.5V Replace
—

4. Operate machine by yourself (trial run) ● Failure codes may not indicate machine
trouble. Temporary electrical failure can oc-
Confirming that the third item above is cur in controller memory, such as low bat-
normal, run startup check on the machine tery output voltage, or open circuit in switch
to determine the cause of failure. If the or sensor. Therefore, make repeated trials
failure cannot be determined, turn off the to erase the accumulated failure codes
engine and get more information from the from the controller memory and confirm
operator. whether the failure codes are displayed af-
5. Perform troubleshooting ter repeated trials. That is to say, "reoccur-
rence" of this trouble is possible.
Conduct deep analysis and determine the
cause of trouble according to the symp- 6. Find out possible causes
toms of the machine and the information Before making a conclusion, check the
displayed on the monitor.
.
most possible causes again and try to de-
De al
termine the root causes of troubles. Make
pt
Remark:
a feasible repair scheme according to your
● Never disconnect harness and hydraulic conclusion.
g n
lines when the engine is running. Oil and
o
water under high pressure and high tem-
perature may squirt and cause personal
in ti
injuries. Shut off then engine when discon-

necting the harness and hydraulic lines.
et a
n
rk er
Ma t
In

7.3 Connector Location and Electrical Circuit Diagram
Location
Connec- No. of Sensor,
Type Name of device Cab Engine
tor No. pin Layout solenoid
circuit circuit
circuit
T-101 Terminal 1 Battery relay coil (positive) M-2 D-1
T-102 Terminal 1 Battery relay coil (negative) M-2 D-1
Battery relay contact (out-
T-103 Terminal 1 M-2 D-1
put)
T-104 Terminal 1 Battery relay contact (input) M-2 D-1
T-106 Terminal 1 Starting motor (B terminal) J-6 L-3
.
De al
T-107 Terminal 1 Alternator (B terminal) K-6 L-5
pt
T-108 Terminal 1 Preheating fuse (21#) M-2 G-9
T-109 Terminal 1 Preheating fuse (17#) M-2 G-9
T-110 Terminal
g n1
o
Body grounding M-1 B-1
T-111 Terminal 1 Body grounding K-6
Preheating resistance wire
in ti
T-112 Terminal 1 J-7 H-9

terminal
T-115 Terminal 1 Starting motor grounding J-6 L-3
Body grounding (at the sides
et a
T-119 Terminal 1 M-1 B-9

of battery)
n
T-201 Terminal 1 Body grounding X-6

rk er
T-202 Terminal 1 Body grounding X-6

K5 R 5 Horn relay X-6 H-9
K6 R 5 Lamp relay X-6 I-9
Ma t
K8 R 5 Top lamp relay X-6 J-9

In
K7 R 5 Parking relay X-6 J-8

KB — 5 Battery relay M-2 D-1
K3 R 5 Starting relay X-6 L-4
KH — 5 Preheating relay Y-6 G-9
K10 R 5 Pilot valve relay X-6 K-1
CN-106F A 2 Junction connector W-6 J-2
CN-142M D 12 Intermediate connector W-6 C-9
CN-131M D 12 Intermediate connector R-5 C-9
CN-302F A 3 Intermediate connector R-6 D-9
CN-301M S 6 Intermediate connector R-6 F-9
CN-132F D 12 Intermediate connector R-5 C-5
CN-1-110 D 6 Intermediate connector AB-4 K-5
CN-121F D 12 Intermediate connector W-6 D-8

Location
circuit circuit
circuit
CN-241M D 12 Intermediate connector W-6 F-8
CN-1-112 3 3 Intermediate connector W-6 C-9
CN-1-111 D 8 Intermediate connector W-6 C-9
CN-7-705 D 12 Monitor panel P-5 D-9
CN-801F H 6 Intermediate connector J-7 K-8
CN-445M S 6 Intermediate connector I-7 F-3
CN-204F A 2 Intermediate connector X-6 C-8
.
CN-412F A 3 Intermediate connector X-6 C-8
De al
pt
CN-112M A 2 Washing motor K-5 K-4
CN-102M A
g n 2 Platform lamp E-5 K-2
CN-104M A 2 Boom lamp (left) E-7 K-1
o
CN-105M A 2 Boom lamp (right) E-7 K-2
Hydraulic oil temperature
in ti
CN-113M A 2 I-7 F-9
sensor
CN-101M S 1 Fuel level sensor F-6 F-9
CN-152M A 2 Intermediate connector W-6 F-8
et a
CN-613F L 6 Safety relay X-6 K-7

n
CN-661F S 16 Intermediate connector W-6 I-8

rk er
CN-161M S 16 Intermediate connector W-6

CN-115M DF 3 Main pressure sensor (front) I-7 F-4
CN-116M DF 3 Main pressure sensor (rear) I-7 F-4
Ma t
CN-128M DF 3 Arm-in pilot sensor I-6 F-5

In
CN-122M DF 3 Arm out pilot sensor I-6 F-4

CN-126M DF 3 Boom-up pilot sensor I-6 F-5
CN-125M DF 3 Boom-down pilot sensor I-6 F-6
CN-124M DF 3 Bucket-curl pilot sensor I-6 F-6
CN-127M DF 3 Bucket-dump pilot sensor I-6 F-6
CN-123M DF 3 Swing pilot sensor I-6

F-7
CN-120M DF 3 Travel pilot sensor (left) I-6 F-7
CN-121M DF 3 Travel pilot sensor (right) I-6 F-8
CN-448M S 2 Speed sensor I-7 F-9
CN-307M H 8 Top lamp switch R-5 C-3
CN-303M H 8 Work lamp switch R-6 C-2
CN-305M H 8 Washer switch R-6 C-2

Location
circuit circuit
circuit
CN-304M H 8 Wiper switch R-6 C-1
CN-104M A 2 Horn switch R-6 E-3
CN-306M H 8 Preheating switch R-5 F-1
CN-207F S 12 Air conditioner unit W-6
CN-113F AMP 2 F. pump solenoid valve I-7 F-2
CN-114F AMP 2 R. pump solenoid valve I-7 F-1
Boom priority solenoid valve
CN-135F AMP 2 J-6 F-2
.
2
De al
Bucket Confluence solenoid
CN-134F AMP 2 J-6 F-3
pt
valve
Boom priority solenoid valve
CN-132F AMP 2 J-6 F-3
g n 1
CN-136F AMP 2 Pilot solenoid valve J-6 L-2
o
Hi/Lo speed travel solenoid
CN-131F AMP 2 J-6 F-1
in ti
valve
CN-133F AMP 2 Swing priority solenoid valve J-6 F-4
F-108 W 1 Coolant temperature sensor J-7 F-8
et a
F-104 W 1 Horn (right) I-5 K-2

n
F-103 W 1 Horn (left) I-5 K-2

CN-616F AMP 81 Controller W-6 A-4
rk er
CN-615F AMP 40 Controller W-6 A-9

CN-800M S 2 Alternator terminal L/R K-6
Ma t
CN-7-707 AMP 2 Cigarette lighter P-4

In
CN-150M D 8 Intermediate connector AE-3

CN-107M HL 7 Radio W-6
PF021 - - Fuse box X-4
CN-1-001M A 2 Speaker (left) AE-6
CN-1-002M A 2 Speaker (right) AD-7
CN-1-103M A 2 Front right lamp AB-6
CN-1-004M A 2 Front left lamp AC-5
CN-1-005 H 1 Cab lamp AE-7

Connector code Description

S SWP type, Yazaki
A/AMP AMP, Japan
D DT type, Japan
H Hebi
HL Hulane Connectors
L Ling Xing Electronic Equipment
DF Delphi, U.S.
W AMP, Japan
Terminal Round terminal
.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

7.3.1 Connector location layout
CN-105M CN-104M CN-101M
.
De al
pt
6
g no
in ti
CN-102M
5
et a
n
rk er
4
Ma t
In
ZX215-1005033
A B C D E F

CN-113M CN-448M F-108

CN-113F T-112
CN-801F
CN-114F
T-106
CN-115M
T-115
CN-116M
T-111
CN-445M
CN-800M
T-107
.
De al
CN-112M
pt
g n CN-124M
CN-125M
o
CN-126M
in ti
F-104
F-103
et a
n
CN-128M
rk er
CN-127M
Ma t
CN-123M
CN-122M
In
CN-121M
CN-120M
CN-131F
CN-132F
CN-133F
CN-134F
CN-135F
CN-136F
ZX215-1005034
G H I J K L M

CN-307M CN-306M CN-132F

CN-305M
CN-304M
9 CN-303M
CN-104M
CN-302
CN-131M
8
CN-301M
.
De al
7
pt
g no
6
in ti
et a
5 CN-7-705
n
rk er
4
Ma t
CN-7-707
In
ZX215-1005035
N O P Q R S T

CN-1-111
CN-661F CN-161M CN-152M
CN-1-112
T-201
CN-241M T-202
K5
CN-121F
K6
K10
CN-142M K3
K7
K8
CN-613F
.
De al
CN-615F
pt
g n CN-616F
KH
o
in ti
CN-412F
et a
n
rk er
Ma t
In
CN-204F
PF021
CN-207F
CN-107M
CN-106F
ZX215-1005036
T U V W X Y Z

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

CN-1-002M
9
CN-1-005
CN-1-001M
8
CN-1-103M
.
De al
pt
6 g no
in ti
5 CN-1-004M
et a
n
4
rk er
CN-1-110
Ma t
3
In
2
CN-150M
ZX215-1005037
AA AB AC AD AE AF

7.3.2 Electrical element circuit diagram (cab circuit) PF021

CN-1-112
F1
CANH
(D-3)
22 20 A
20
1 1
CANL 120ȍ resistance F3 5A
2 2 23
CN-7-705
CN-616F CANH
3
(D-12)
3
24 F4 15A
Monitor
CANL
Ground 1
29
4 4 4
25 F5 5A
8 8 8
2 CN-1-111 22 21
(D-8) 9 9 9
3 0 10 10 10 F7 10A
1 1 26
24Vpower 4 2 2 12 12 12
CN-131M CN-302F
9
5 3 3 CN-142M F9 5A
50 (D-12) 50
(D-12)
50 (A-3) 50 28
6 1 1 1 1
Fuel ctrl dial

1 1 1
7 5062 506 506 506 5A
2
00
2 2 2 2
00 3 3 00 3
2 29 F10
8 00 3 3 3 3
4 4
9 20 A
5 5 42 F11
10 6 6
11 43 F14 10A
12 CN-412F
AIN16 13 (A-3)
49 F15
15A
14 CAN+ 1 1
B
15 2 2 70 F17 10A
16
CAN- 3 3
GPS CN-121F
17 (D-12)
0
8 18
19
43
1
2
1
2 2
4
2
4
CN-204F
20 (A-2) 5 5
21 9 9
10 10
22
11 11 1 3 4 5 8 9 10 11 12
23 12 12 CN-241M
24 (D-12)
1 3 4 5 8 9 10 11 12
25
26
27
28
29
.
30
31
De al
32
33
Fuel control knob voltage 34
pt
7 35
36
37
38
39
40
g n 41
42
43
44
45
o
46
47
48
6 49
in ti
50
51
52
53
00
s GND 54 28 X-1
00
s GND 55
50
s PWR 56
57 CAN- 70 X-2
58
59 CAN+
et a
60
61
62
CN-132F
63
5
(D-12)
n
64 1
65 2
1
33 X-3
2
66 3 3 24 X-4
67 4 4 25 X-5
68 5
rk er
5
69
37 X-6
70 12 12
71
36 X-7
72
00
s GND 73
s PWR 74
50 35 L X-8
50
s PWR 75
72 X-9
76 CAN+
CAN-
CAN+ 77
35 H X-10
Ma t
4 CAN- 78
79
23 X-11
80
81
X-12
In
CN-615F
82 X-13
83
84
85 X-14
86
87
88
89
90
23 31
3 91
92 Top lamp switch 21
20
93 Horn switch
94 CN-104M
95 70 72
96
97 CN-307M
98
99 TERMINAL
B BRACCR1 R2 C
100 Work lamp switch HEAT
101
OFF Start switch
ON
102 START
2 103
104
24 33 22 13
105 CN-303M
106
107 Washer switch
22 11
108 11
109 Stabilized voltage diode 25 37 13 13
110 9 9
CN-152M CN-153M
111 1 2 1 2 CN-332M
CN-305M
112 S-6
113
0 0 42 0 42 Wiper switch
Ground 114
0
Ground 115
36
116 25
117
35 L 1 2 3 4 5
118
1 2
42
24Vpower supply 119
1 35 H 1 2 3 4 5
42
24Vpower supply 120 KB
121
122
CN-304M Battery relay + - + -
Chassis GND
ZX215-1005038
A B C D E F

★ This circuit diagram has been compiled by extracting the wiper system and each switch control system
from the overall electrical circuit diagram.
Access lamp
28
Horn relay Lamp relay Top lamp relay

9
K5 K6 K8
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
31 0 23 32 33 0 24 34 72 0 70 71 0
8
CN-1-110
(D-6) Wiper
0
1 1
X-1 25
.
2 2
36 3
De al
M
CN-161F 3
X-2 (S-16)
35H 4 4
1 1 7
pt
3 3
4 4
5 5 35 L
6 6 5 5
X-3
X-4
g no
7
8
7
8
X-5
X-6 6
CN-112M
in ti
X-7 (A-2) Washer motor
0
1 1
X-8 2 2 37 M
X-9
X-10
et a
Right top lamp

X-11
1 1
0
5
n
2 2 71
X-12
X-13 Left top lamp

rk er
1 0
1
X-14 2 2 71
CN-150M
(S-8) F-104
R+
1 1
R+
(W-1)
R- R- Horn
2 2 4
Ma t
L+ L+ 1 1
3 3 CN-661F
L- 4 4 L-
(S-12)
0
5 5 0 32 F-103
3 3
71 71
(W-1)
In
6 6 34
4 4
0 7 7 0
1 1
26 8 8 26
F6
21 20 b CN-102M Rotating stage
(A-2) work lamp
F8
0
1 1
0 3
21 38 34 34
2 2
CN-102M Left boom

1 (A-2)
20 b
R+
0
work lamp
L+
2 1 1
3 2 2 34
0
4 CN-102M
20 b
5 Right boom
R- (A-2) work lamp
6 0
L- 1 1
7
CN-107M
2 2 34 2
Radio panel
Right speaker
Compressor clutch
57 1
61 a
0 57 4 Left speaker
60 a
1 2 5
0 6 0 0 Cab lamp
CN-109M 38 7 26
1 1
38 26
8 2 2
CN-207F
Air conditioner panel
CN-442F
(S-12)
CN-7-111
(S-8)
1
60a 60a
4 4 7 7
61a 61a Ex air sensor
8 8 8 8
ZX215-1005039
G H I J K L

7.3.3 Electrical control circuit diagram (engine circuit)

CN-332M
S-6 TERMINAL B BR ACCR1 R2 C
T-102 22 22
CN-616F T-119 T-110 11 11 HEAT
Body ground CN-241F
13 13 OFF
1 0 20
(D-12) 9 9 ON
Grounding 2 1 1 22 11 8 11
START
3 - + - + 2 2 10
8
22 13 16 11
4 42 20 20
F1 20A22
Controller power supply 5 9 9 F2 5A10
21 21
6 11 11
PF021
7
9 8
CN-152M CN-153M
9
10 1 2 1 2
11
12 0 42 0 42
13
14 506
Throttle position feedback 15
16
17
18
19
20 X-1
21 21
22
8 23
24
25
26 X-2
27 10
28
29
30 X-3
21
.
31
32
De al
33
34
35 13 X-4
pt
36
37
7 38
39
40 X-5
41 18
g n
42
43
44
45 22 X-6
46
o
47
48
49
50 12 X-7
6
in ti
51
52
53 00
54 00
55 50 X-8
5Vpower supply 56 0
57
58
59 606 X-9
60
et a
61
62 X-10
63 50
64
n
65
5 66 507 X-11
67
68 X-12
69 MT+
rk er
70
71 X-13
72 00 00
73 50
5Vpower supply74 X-14
50 MT-
5Vpower supply75
76
77 F16 CN-221M
78
Ma t
79 1 1
4 80
81
CN-615F
In
CN-161F
82 27
83 12 12 105
84
85 14 14
Pilot switch
86
87
88
89
90
91
92
3 93
94
95
96
97
98
99
100
101
102
103
104 MT+
Throttle motor output signal+ 105
106
2
107
108
109
110
111
112 MT- 7 7
113
Grounding 114
0
Grounding 115
0 CN-331F
116
117 21
0 105 11 12
118 CN-241F F11 21
24Vpower supply
42 T-102 T-101 T-103 T-104
1 2 3 4 5 Preheat switch 1 2 3 4 5
119 4
24V power supply120 42 1 2
1 2 3 4 5
K3 1
1 2 3 4 5 2 3 4 5
121
1
1 2 3 4 5
122 KB 16 18
Battery relay
Pilot valve relay CN-306M Locking relay
ZX215-1005040
A B C D E F G
★ This circuit diagram has been compiled by extracting the engine preheat system, startup system and
governor system from the overall electrical circuit diagram.
T-112
17
Preheat relay Parking relay
KH
1 2 3 4 5 K7 1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
F13 160A
T-108 T-109
0 18 16 17 0 13 64 63 65 9
7 7 17 Preheater
9 9
14
CN-661M 12 12
(S-16)
10 10
Preheater indicator
15 15
CN-442F
(D-12) 17
1 1
0 2 2
CN-121F
CN-661F
CN-801F
22
64 B
8
(D-12) (H-6) 63 A
65 P2
(S-16)
X-1 21 5 5 606 22 P1
1 1 1 1 E
64
65
2 2 Parking motor
X-2 10 6 6 63 0
12 3 3
0
X-3 7 7 4 4
21 65
63
9 9 6 6
.
X-4 13
De al
64
10 10
18
X-5
7
pt
X-6 22
X-7 12
g n
X-8 0 CN-613F
12 a
1 1
o
X-9 606 14 12a
S
2 2 14
L Safety relay
6
10
10 R
3 3 47
P
X-10
in ti
50 47
4 4 0
0
6 6
X-11 507
X-12 MT-
et a
X-13 00
5
n
X-14 MT+ 10
14 R
21 L
47 B
P
E
rk er
0
Generator
Body ground
4
Ma t
In
CN-112M
1 2
12 a 12
CN-111F
1 1
12
2 2
12 a
21
E
0
Starting motor
3
A3 Body ground
F-310 Charging indicator

10
1 1
14
F-311
2 2
Connector 282080-1 CN-316F
(AMP-2)
1 2
606
1 1
2
2 2
Pilot solenoid valve
M13
(S-6)
50
1 1
507
2 2 1
2 Throttle motor
3
MT-
3 3 5 AC-2000
6
00
MT+
5 5 1
6 6
ZX215-1005041
G H I J K L M

7.3.4 Electrical control circuit diagram (sensor and solenoid valve circuit)
CN-101M
509 (S-1)
CN-616F 1 1 Fuel level sensor
CN-448M
1 (S-2)
Grounding 2 108A 1 1
3 108B Engine speed sensor
4 2 2
9 Controller power supply 5

6 CN-113M
(A-2)
7
8 511 1 1
9 42 Hydraulic oil temp. sensor
2 2
10
Oil level sensor 11 CN-152M
12 (A-2)
13 0
14 1 1 240欧
15 511 2 2 w1/4 F-108
16 (W-1)
17 510 Coolant temp. sensor
18
Speed sensor GND 19 508
8 20
21 0
Oil pressure switch
22
CN-121M
23 (DF-3)
24 50 A A
25 0 Right travel pilot
26 B B
27 201 C C
pressure sensor
28 CN-120M
29 50 (DF-3)
.
Coolant temp. sensor 30 A A
Hydraulic oil temp. sensor 31 0 Left travel pilot
De al
B B
32 200 C C
pressure sensor
33 CN-123M
34
pt
(DF-3)
50
7 35
36 0
A A
Swing pilot
B
37 208
B
pressure sensor
Pulse input 38 C C
39 CN-124M
40 (DF-3)
50
g n 41
42
43
44
0
205
A
B
C
A
B
C
Bucket curl pilot
pressure sensor
45 CN-127M
o
(DF-3)
46 50 A
47 0
A
Oil pressure switch 48 B B Bucket dump pilot
6 Travel sensor (left) 49 204 C C

pressure sensor
in ti
Bucket dump sensor 50 CN-125M
Boom lower sensor 51 (DF-3)
Arm out sensor 52 50 A A
Rear pump main pressure sensor 53
0 B B Boom lower pilot
s GND 54 207 C pressure sensor
s GND 55 C
s PWR 56 CN-126M
57 (DF-3)
58
50 A A
59 0 Boom raise pilot

et a
B B
60 206 C C
pressure sensor
61 CN-128M
62 (DF-3)
63 50
5 A A
n
64 0 B B Arm in pilot
65 203 C
pressure sensor
66 C
Travel sensor (right) 67 CN-122M

Swing sensor 68 (DF-3)
50
rk er
Bucket curl sensor 69 A A

Boom raise sensor 70 0 B B
Arm out
Arm in sensor 71 202 C C
pressure sensor
Front pump main pressure sensor 72
CN-115M
5V power supply GND 73 (DF-3)
5Vpower supply GND 74
5Vpower supply GND 75
50 A A
76 0 B B
Front pump
77 501 C C
pressure sensor
4
Ma t
78 CN-116M
79 50 (DF-3)
80 A A
81 0 B B
Rear pump
CN-615F 502 pressure sensor
In
C C
Hi/Lo speed travel
CN-133F
82 608 (AMP-2)
1 Swing priority-A4
83 0
1
proportional
84 2 2
solenoid valve
85
86 CN-134F
87 604 1 1
(AMP-2) Bucket confluent-A5
Front pump solenoid proportional valve 88 0 2 2 proportional
Rear pump solenoid proportional valve 89 solenoid valve
90
3 91 602
CN-132F
(AMP-2)
Boom priority 1-A4
92 1 1
93 0 2 2 proportional
solenoid valve
94 CN-135F
95 (AMP-2)
96 603 1 1 Boom priority 2-A4
Swing priority solenoid valve 98 solenoid valve
Bucket confluent valve 99
Boom priority 1 100
Boom priority 2 101
102
103
104
105
2 106
107
108
109
110 CN-113F
(AMP-2)
111
112 702 1 1 Front pump
Grounding 114 CN-114F
solenoid valve
Grounding 115 (AMP-2)
116 703 1 Rear pump
117 0
1
proportional
118 2 2
solenoid valve
24Vpower supply 119 CN-131F
1 24Vpower supply 120

121 24Vpower supply 607
(AMP-2)
1 1 Hi/Lo speed travel

122 0 2 2 solenoid valve
ZX215-1005042
A B C D E F G

7.3.5 SWP type connector
Male (Plug) Female (Socket)
7222-7414-40 7123-7414-40 (No.of pin: 1)
.
De al
pt
g no
in ti
7222-1424-40 7123-1424-40 (No.of pins: 2)

et a
n
rk er
7222-7464-40 7123-7464-40 (No.of pins: 6)

Ma t
In
7222-7484-40 7123-7484-40 (No.of pins: 8)
7222-7564-40 7123-7564-40 (No.of pins: 16)

7.3.6 A/AMP type connector
Male (Plug) Female (Socket)
282104-1 282080-1 (No.of pin: 2)
.
De al
pt
g no
282105-1 282087-1 (No.of pin: 3)
in ti
et a
n
rk er
174354-2 174352-2 (No.of pin: 2)

Ma t
In
1473252-1 1473255-1 (No.of pin: 40)
1473244-1 1473247-1 (No.of pin: 81)

7.3.7 DT type connector
Shell (Plug) Shell (Socket)
A B B A
DT06-2S DT04-2P
.
A
De al
A B
B
pt
g no
C C
DT06-3S DT04-3P (No.of pin: 3)
in ti
1 6 6 1
et a
2 5 5 2
n
3 4 4 3
rk er

5 8
8 5
Ma t
In
1 4 4 1
12 7 7 12
1 6 6 1
DT06-12S DT04-12P (No.of pin: 12)

7.4 Failure Symptoms and Troubleshooting Codes
Troubleshooting
No. Symptom
Code E mode H mode (Engine)
Action to be taken concerning Service Code, User Code and Failure Code
1 Display User Code in monitor panel
Display Service Code in electrical system after checking According
2
failure history to displayed
Display Failure Code in mechanical system after checking code
3
failure history
Engine-related failure
Engine does not start up easily. (It always takes some
.
4 S-1
De al
time to start up the engine)
pt
5 Engine misfires. E-1 S-2
6 Color of exhaust gas is too dark.(Incomplete combustion) S-3
7
g n
Engine pickup is poor.
o
S-4
8 Engine runs rough or is unstable. E-2 S-5
in ti
9 Engine is short of output, or lacks power H-2 S-6

10 Auto Idle fails. E-4 H-5
Excessive engine oil consumption, or color of exhaust gas
et a
11 S-7
is blue
n
12 Premature engine oil contamination S-8

13 Excessive fuel consumption S-9
rk er
Engine cooling water is mixed with engine oil, spurts out

14 S-10
or decreases
15 Engine oil amount increases. (Water or fuel gets in) S-11
Ma t
16 Abnormal noises are heard S-12

In
17 Excessive vibrations are caused S-13

Failure related to work equipment, swing and travel
18 Power supply of machine cannot be cut off. E-3
19 There are abnormal noises from around hydraulic pump H-4
20 All work equipment, travel and swing do not move H-3
21 Speeds of all work equipment, travel and swing are slow H-1 S-6
When Machine Swings and Travels Simultaneously,
22 H-13
Travel Speed Lowers Largely
Work equipment-related failure
23 All the equipment do not work E-6
24 Cylinder do not work singly H-9
25 Drift of cylinder is too large H-10
26 Work equipment time lag is too big H-11

Troubleshooting
No. Symptom
Code E mode H mode (Engine)
Other work equipment moves, when specific work equip-
27 H-12
ment is relieved
28 Boom-up speed or power is low. E-7 H-6
29 Arm speed or power is low. E-8 H-7
30 Bucket speed or power is low. E-9 H-8
Travel-related failure
31 Travel speed or power is low. E-10 H-15
32 Dual Speed Travel Not Functioning E-13
33 Machine tends to swerve while in travel H-14
.
34 Machine is difficult to steer, or lacks power H-16
De al
pt
35 Travel speed cannot be shifted H-17
36 Track shoe does not move (only on one side)
g n H-18
Swing-related failure
o
37 Machine does not swing H-19
38 Swing acceleration is poor, or swing speed is slow H-20
in ti
Upper structure overruns remarkably when stopping

39 H-21
swinging
et a
40 Large shock is made when stopping swinging H-22

41 Large sound is made when stopping swinging H-23
n
42 Hydraulic drift of swing is large H-24

rk er
Monitor panel-related failure

43 Monitor display is blank. E-11
Ma t
44 Monitor displays nothing. E-12

45 Engine coolant temperature reading is incorrect. E-14
In
46 Fuel level reading is incorrect. E-15

47 Arm-in pilot pressure reading is incorrect. E-17
48 Arm-out pilot pressure reading is incorrect. E-18
49 Boom-up pilot pressure reading is incorrect. E-19
50 Boom-down pilot pressure reading is incorrect. E-20
51 Bucket-close pilot pressure reading is incorrect. E-21
52 Bucket-open pilot pressure reading is incorrect. E-22
53 Swing pilot pressure reading is incorrect. E-23
54 Left travel pilot pressure reading is incorrect. E-24
55 Right travel pilot pressure reading is incorrect. E-25
Other failure
56 Preheating function fails. E-5
57 Wiper does not work. E-16

7.5 Troubleshooting with an Event Code
Information in troubleshooting table .......................................................................................... 7-29

E111 (controller memory failure (FROM)) .................................................................................. 7-30
E212 (throttle motor current & motor connection abnormal) ..................................................... 7-31
E213 (throttle motor operation suspends) ................................................................................ 7-32
E214 (throttle motor working range abnormal) .......................................................................... 7-33
E015 (power supply voltage abnormal) ..................................................................................... 7-34
E116 (controller internal temperature abnormal) ....................................................................... 7-35
E017 (abnormal output of 5v power supply in sensor) .............................................................. 7-36
E118 (abnormal communication between controller and monitor) ............................................ 7-37
E320 (abnormality in front pump output pressure) .................................................................... 7-38
.
E321 (abnormality in rear pump output pressure) ..................................................................... 7-39
De al
E322 (abnormality in arm-in pilot pressure)............................................................................... 7-40
pt
E323 (abnormality in arm-out pilot pressure) ............................................................................ 7-41
E324 (abnormality in boom-raise pilot pressure) ...................................................................... 7-42
g n
E325 (abnormality in boom-lower pilot pressure) ...................................................................... 7-43
o
E326 (abnormality in bucket-curl pilot pressure) ....................................................................... 7-44
E327 (abnormality in bucket-dump pilot pressure) .................................................................... 7-45
in ti
E328 (abnormality in swing pilot pressure ................................................................................. 7-46

E329 (abnormality in left travel pilot pressure) ......................................................................... 7-47
et a
E330 (abnormality in right travel pilot pressure) ........................................................................ 7-48

E231 (abnormality in fuel control dial set voltage) ..................................................................... 7-49
n
E237 (abnormality in hydraulic oil temperature) ........................................................................ 7-50

rk er
E541 (abnormality in engine speed) .......................................................................................... 7-51

E450 (abnormality (a) in front pump proportional solenoid coil current) .................................... 7-52
E450 (abnormality (b) in front pump proportional solenoid coil current) .................................... 7-53
Ma t
E451 (abnormality (a) in rear pump proportional solenoid coil current)..................................... 7-54
E451 (abnormality (B) in rear pump proportional solenoid coil current) .................................... 7-55
In
E452 (abnormality (A) in swing priority proportional solenoid coil current)................................ 7-56
E452 (abnormality (B) in swing priority proportional solenoid coil current)................................ 7-57
E453 (abnormality (A) in bucket confluence proportional solenoid coil current) ....................... 7-58
E453 (abnormality (B) in bucket confluence proportional solenoid coil current) ....................... 7-59
E455 (abnormality (A) in boom priority 2 proportional solenoid coil current) ............................. 7-60
E455 (abnormality (B) in boom priority 2 proportional solenoid coil current) ............................. 7-61
E460 (abnormality in dual speed travel solenoid valve) ............................................................ 7-62

Information in troubleshooting table
User Code Service Code

Trouble Title of failure shown in failure history
Display on monitor —
Failure description
Failure is described on the monitor display.
When failure is detected, the controller has taken action to protect the affected
Response from controller
system or equipment.
Symptom of machine Symptom that is shown on the machine due to action of controller.
Cause Standard value in normal state and remarks on troubleshooting

Possible causes and standard value in normal state
.
De al
pt
2 <Inclusion>
● Standard value under normal condition can be used to judge pos-
3
g n sible causes
4 Possible causes ● Reference for passing the above "Good" or "No Good" judgement
o
of trouble (Given
in ti
numbers are ref- <Symptom of Wiring Harness Failure>

erence numbers, ● Open circuit
which do not indi- Faulty contact with connector or open circuit in wiring harness
et a
cate priority)
5 ● Faulty grounding
n
An ungrounded wiring is grounded.

rk er
● Short circuit
A wiring has mistaken contact with a 24 V electric circuit.
Ma t
In
Related circuit diagram
This is part of the circuit diagram which shows the portion where the failure occurred.
● Connector No.: A connector number Indicates a connector.
● Arrow: An arrow roughly indicates the installing location.

E111 (controller memory failure (FROM))

Trouble Controller memory fails and the system slows down.
E111 11
When the power is on, abnormality is detected by checking through FROM sum-
Failure description
mation and RAM verification.
Response from controller Stop the operation of motor and solenoid coil.
Symptom of machine Engine acceleration fails and the machine acts slowly. .
Cause Standard value in normal state/Remarks on troubleshooting

Possible causes and standard value in
1 Internal failure No troubleshooting can be done for failure occurs in the inner of controller. (If
of controller this failure occurs, replace the controller.)
.
2
De al
normal state
pt
3 g no
4
in ti
5
et a
n
rk er
Ma t
In

E212 (throttle motor current & motor connection abnormal)
User Code Service Code Throttle motor loading circuit is abnormal and the
Trouble
E212 12 engine acceleration fails.
When the power is on, magnitude of throttle motor coil current is out of the
Failure description
range of 0.1A~1.8A and lasts for 2 seconds.
Response from controller The controller stops the motor driving system when this failure is detected.
Symptom of machine Engine acceleration fails and the machine acts slowly.

● Turn engine start switch to OFF position. Keep it at OFF position to per-
Failure of throt-
1 form troubleshooting.
tle motor coil
.
Between CN-445M ③ and ⑥ Resistance 12.2 Ω
De al
pt
2 Open circuit of form troubleshooting.
harness Unplug the controller and measure the resistance
g n Resistance 12.2 Ω
between pin 113 and pin 105.
o
Short circuit form troubleshooting.
in ti
3 of harness Unplug the connector CN-445M and measure the

(grounded) resistance between motor ③ ( ⑥ ) and the hous- Resistance ≥2M Ω
ing.
et a
No troubleshooting can be done for failure occurs in the inner of controller.

Internal failure
n
4 (Except for the above reasons, the controller must be replaced in case of
of controller
failure.)
rk er
5
Ma t
In
CONTROLLER
CN-445M THROTTLE MOTOR
50# GREEN
SENSOR 5V 75 1 1
507# WHITE
THRTL FEEDBACK VOLT. 55 2 2
MT- 3 RED
MT- 113 3 M
4 4
GND WIRE 55
0#
5 5 YELLOW
MT+ 105
MT+ BLUE
6 6
CAB CHASSIS HARNESS
ZX215-1005071

E213 (throttle motor operation suspends)
User Code Service Code Operation of throttle motor suspends and engine
Trouble
E213 13 acceleration fails.
The controller monitoring accuracy deviates by over 5%, which is normally
Failure description
between 0.8 - 4.2 Voltage, after the system is powered on for 30 seconds.
Response from controller The controller stops the motor driving system when this failure is detected.

Failure of throttle
motor coil
.
De al
● Turn engine start switch to OFF position. Then, keep it at ON position to
pt
Failure of 5V
2 perform troubleshooting.
power supply
g n Between CN-445M ① and ⑤ Voltage About 5V
Open circuit of
o
form troubleshooting.
3 Unplug the controller and measure the resistance
harness Resistance 12.2 Ω
in ti

Failure of throttle
position sensor
et a
Between CN-445M ② and ground Voltage 0.8V~3.5V

Short circuit ● Turn engine start switch to OFF position. Keep it at OFF position to per-
n
5 of harness Unplug the connector CN-445M and measure the
rk er
(grounded) Resistance ≥2M Ω

resistance between motor ③ ( ⑥ ) and the housing.
Internal failure of
Ma t
controller
failure.)
In
CONTROLLER
50# GREEN
SENSOR 5V 75 1 1
507# WHITE
MT- 3 RED
MT- 113 3 M
4 4
GND WIRE 55
0#
5 5 YELLOW
MT+ 105
MT+ BLUE
6 6
CAB CHASSIS HARNESS
ZX215-1005071

E214 (throttle motor working range abnormal)
User Code Service Code Throttle motor working range is abnormal and the
Trouble
E214 14 engine returns to auto idle.
The voltage is below 0.8V at the minimal stroke or above 4.2V at the maximal
Failure description
stroke, and it lasts for 100msec when the power is on.
Response from controller Turn the throttle to idle speed.
Symptom of machine Engine returns to auto idle.

Failure of throt-
tle motor coil
.
De al
pt
Failure of 5V
power supply
g n Between CN-445M ① and ⑤ Voltage About 5V
Open circuit of
o
3 Unplug the controller and measure the resistance
harness Resistance 12.2 Ω
in ti

Failure of ● Turn engine start switch to OFF position. Then, keep it at ON position to
4 throttle position perform troubleshooting.
et a
sensor Between CN-445M ② and ground Voltage 0.8V—3.5V

n
Short circuit form troubleshooting.

Unplug the connector CN-445M and measure the
rk er
5 of harness
(grounded) resistance between motor ③ ( ⑥ ) and the hous- Resistance ≥2M Ω
ing.
Ma t
Internal failure
of controller
In
failure.)
CONTROLLER
50# GREEN
SENSOR 5V 75 1 1
507# WHITE
MT- 3 RED
MT- 113 3 M
4 4
GND WIRE 55
0#
5 5 YELLOW
MT+ 105
MT+ BLUE
6 6
CAB CHASSIS HARNESS
ZX215-1005071

E015 (power supply voltage abnormal)

Trouble Power supply voltage is abnormal.
15 E015
Failure description Voltage of power supply is above 36V when the machine is running.
Response from controller The system stops the motor and solenoid valve automatically.

Failure of ● Turn engine start switch to OFF position. Keep it at OFF position to perform
1 power sup- troubleshooting.
ply Measure battery voltage Voltage ≤25V
.
● Turn engine start switch to OFF position. And Then, keep the engine running
De al
normal state
Alternator to perform troubleshooting.
pt
2 Measure the voltage between the alternator terminal
abnormal Voltage About 28V
B and ground.
g n
3
o
in ti
4
et a
CN-613 SAFETY RELAY

n
START SWITCH 1
L S
TERMINAL B BR ACC R1 R2 C 2
rk er
3 R
HEAT 4
E P
OFF 5
ON 6
Ma t
START
In
1 2 F-107
CN-800M
G
R
L P
B E
0
ALTERNATOR
- + - +
BATTERY RELAY
0
CAB CHASSIS HARNESS
ZX215-1005072

E116 (controller internal temperature abnormal)
User Code Service Code Internal temperature of controller is abnormal. Engine

Trouble
E116 16 acceleration fails and the machine acts slowly.
Internal temperature of controller keeps above 80°C or below -30°C for 10 sec-
Failure description
onds when the power is on.
Response from controller The controller stops the motor and the solenoid coil.
Possible causes and standard value in nor-

Internal
No troubleshooting can be done for failure occurs in the inner of controller. (If this
1 failure of
failure occurs, replace the controller.)
.
controller
De al
pt
2
mal state
3
g no
in ti
5
et a
n
rk er
Ma t
In

E017 (abnormal output of 5v power supply in sensor)

Trouble Abnormal output of power supply in sensor
E017 17
The controller detects out over current or short circuit of sensor power source
Failure description
output when the power is on.
Response from controller Only output alarm is enabled.
Symptom of machine —

Possible causes and standard value in normal
Short circuit ● Turn engine start switch to OFF position. Keep it at OFF position to perform
troubleshooting.
1 in harness Measure the resistance between pin 56, pin 75, pin 74 of
.
Resistance ≥2M Ω
De al
(grounded) controller KC-MB and the ground.
pt
Internal
No troubleshooting can be done for failure occurs in the inner of controller. (Except
2 failure of
for the above reasons, the controller must be replaced in case of failure.)
g n
state
controller
o
3
in ti
4
et a
5
n
rk er
Ma t
In

E118 (abnormal communication between controller and monitor)
User Code Service Code Abnormal communication between controller and

Trouble
E118 18 monitor
Communication of monitor is interrupted for 5 consecutive times when the
Failure description
power is on.

Failure of CAN
resistance
.
Between CN-7-709 ① and ② Resistance 60 Ω
De al
pt
Open circuit of Unplug the controller and measure the resistance
2 ≤1 Ω
g n
state
harness between pin 60 and CN-7-705 ③

Resistance
Unplug the controller and measure the resistance
o
≤1 Ω
between pin 78 and CN-7-705 ④
in ti
Internal failure
of controller
failure.)
et a
4
n
rk er
CN-7-709
CANH
1 1
120ȍ RESISTANCE
2 2
Ma t
CANL
CONTROLLER CN-7-705
CANH
In
3 3 3
MONITOR
CANL 4 4 4
29 8 8 8
22
CANH 60 CN-1-111 9 9 9
0 10 10 10
1 1
CN-441 2 2 12 12 12
CANL 78 3 3 3 3
1 1 F1 20A
22
F10 5A
29
20
21
PWR PWR
CAB CHASSIS HARNESS
ZX215-1005073

E320 (abnormality in front pump output pressure)
User Code Service Code Front pump output pressure is abnormal. Only output
Trouble
E320 20 alarm is enabled. .
A pressure feedback voltage other than 0.25~4.75V keeps more than 200msec
Failure description
when the power is on.

Failure of 5V form troubleshooting.
1
.
power supply Between CN-115M A and B Voltage About 5V
De al
pt
Open circuit of form troubleshooting.
2
g n
signal wire Between CN-115M C and pin 72 of controller Resistance
≤1 Ω
Between CN-115M B and ground ≤1 Ω
o
in ti
3 of signal wire form troubleshooting.

(grounded) Between CN-115M C and ground Resistance ≥2M Ω
Failure of sen-
et a
sor Between CN-115M C and ground Voltage 0.5±0.2V
n
rk er
5
Ma t
CONTROLLER FRONT PUMP

In
CN-446M PRESS. SENSOR

501#
FRONT PUMP PRESSUSRE 72 C SIGNAL
SIGNAL COLLECTING PORT
00#
54 B GND WIRE
GND WIRE
50#
5V　PWR SUPPLY 56 A 5V
CAB CHASSIS HARNESS
ZX215-1005074

E321 (abnormality in rear pump output pressure)
User Code Service Code Reading of rear pump output pressure is abnormal.
Trouble
E321 21 Only output alarm is enabled. .
Failure description

Failure of 5V
power supply
.
Between CN-116M A and B Voltage About 5V
De al
pt
2 Between CN-116M C and pin 53 of controller ≤1 Ω
signal wire
g no
Between CN-116M B and ground
Resistance
≤1 Ω
in ti

● Turn engine start switch to OFF position. Then, keep it at OFF position to
Failure of sen-
et a

n
5
rk er
Ma t
CONTROLLER CN-447M REAR PUMP

In
PRESS. SENSOR
REAR PUMP PRESSURE
502#
53 C SIGNAL
SIGNAL COLLECT PORT
00#
GND WIRE 54 B GND WIRE
50#
CAB CHASSIS HARNESS
ZX215-1005075

E322 (abnormality in arm-in pilot pressure)
User Code Service Code Arm-in pilot pressure is abnormal. Only output alarm
Trouble
E322 22 is enabled. .
Failure description
Symptom of machine The arm in motion is slow.

Failure of 5V
power supply
.
De al
pt
Open circuit form troubleshooting.
of signal wire
g no
Resistance
≤1 Ω
in ti

Failure of
et a
sensor Between CN-128M C and ground Voltage 0.5±0.2V

n
5
rk er
Ma t
CONTROLLER CN-428M ARM-IN PILOT

In
PRESS. SENSOR
203#
ARM-IN PILOT PRESSURE 71 C SIGNAL
00#
50#
CAB CHASSIS HARNESS
ZX215-1005076

E323 (abnormality in arm-out pilot pressure)
User Code Service Code Reading of arm-out pilot pressure is abnormal. Only
Trouble
E323 23 output alarm is enabled.
A pressure feedback voltage other than 0.25 – 4.75V keeps more than
Failure description
200msec when the power is on.
Symptom of machine Arm-out motion is slow.

Failure of 5V
power supply
.
De al
● Turn engine start switch to OFF position. Keep it at OFF position to perform
pt
Open circuit troubleshooting.
of signal wire
g no
Resistance
≤1 Ω
3 of signal wire troubleshooting.
in ti

Failure of sen-
et a

n
5
rk er
Ma t
CONTROLLER ARM-OUT PILOT

In
CN-122M
PRESS. SENSOR
ARM-OUT PILOT PRESSURE
202#
52 C SIGNAL
00#
50#
CAB CHASSIS HARNESS
ZX215-1005077

E324 (abnormality in boom-raise pilot pressure)
User Code Service Code Reading of boom-raise pilot pressure is abnormal.

Trouble
Failure description
Symptom of machine Boom-raise motion is slow.

Failure of 5V
power supply
.
De al
pt
2 Between CN-126M C and 70 pin of controller ≤1 Ω
of signal wire
g no
Resistance
≤1 Ω
in ti

Failure of
et a

n
5
rk er
Ma t
CONTROLLER CN-126M BOOM-RAISE PILOT

In
PRESS. SENSOR
BOOM-RAISE PILOT PRESS. 206#
70 C SIGNAL
00#
50#
CAB CHASSIS HARNESS
ZX215-1005078

E325 (abnormality in boom-lower pilot pressure)
User Code Service Code Reading of boom-lower pilot pressure is abnormal.

Trouble
Failure description
Symptom of machine Boom-lower motion is slow.

Failure of 5V
power supply
.
De al
pt
of signal wire
g no
Resistance
≤1 Ω
in ti

Failure of
et a

n
5
rk er
Ma t
CONTROLLER CN-125M BOOM-LOWER PILOT

In
PRESSURE SENSOR
207#
BOOM-LOWER PILOT PRESS 51 C SIGNAL
00#
50# 5V
5V　PWR SUPPLY 56 A
CAB CHASSIS HARNESS
ZX215-1005079

E326 (abnormality in bucket-curl pilot pressure)
User Code Service Code Reading of bucket-curl pilot pressure is abnormal.

Trouble
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200msec
Failure description
Symptom of machine Bucket-curl motion is low.

Failure of 5V
power supply
.
De al
pt
Open circuit of troubleshooting.
2 Between CN-124M C and 69 pin of controller ≤1 Ω
signal wire
g no
Resistance
≤1 Ω
in ti

Failure of sen-
et a

n
5
rk er
Ma t
CONTROLLER CN-124M BUCKET-DIG PILOT

In
PRESSURE SENSOR
BUCKET-DIG PILOT PRESS.
205#
69 C SIGNAL
00#
50#
CAB CHASSIS HARNESS
ZX215-1005080

E327 (abnormality in bucket-dump pilot pressure)
User Code Service Code Reading of Bucket-dump pilot pressure is abnormal.

Trouble
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200msec
Failure description
Symptom of machine Bucket-dump motion is low

Failure of 5V
power supply
.
De al
pt
signal wire
g no
Resistance
≤1 Ω
in ti

Failure of sen-
et a

n
5
rk er
Ma t
CONTROLLER BUCKET-DUMP PILOT

CN-128M
In
PRESSURE SENSOR
204#
BUCKET-DUMP PILOT PRESS.
50 C SIGNAL
00#
50#
CAB CHASSIS HARNESS
ZX215-1005081

E328 (abnormality in swing pilot pressure
User Code Service Code Reading of swing pilot pressure is abnormal. Only
Trouble
E328 28 output alarm is enabled. .
Failure description
Symptom of machine Swinging motion is slow.

Failure of 5V
power supply
.
De al
pt
signal wire
g no
Resistance
≤1 Ω
in ti

Failure of sen-
et a

n
5
rk er
Ma t
CONTROLLER CN-123M SWING PILOT

In
PRESS. SENSOR
208#
SWING PILOT PRESSURE
68 C SIGNAL
00#
50#
CAB CHASSIS HARNESS
ZX215-1005082

E329 (abnormality in left travel pilot pressure)
User Code Service Code Reading of left travel pilot pressure is abnormal.
Trouble
Failure description
Symptom of machine Left travel speed is low. Travel deviates.

Failure of 5V
power supply
.
De al
pt
signal wire
g n Resistance
Between CN-120M B and ground ≤1 Ω
o
troubleshooting.
in ti
3 of signal wire
Failure of sen-
perform troubleshooting.
et a
4
sor
Between CN-120M C and ground Voltage 0.5±0.2V
n
5
rk er
Ma t
CONTROLLER L. TRAVEL PILOT

In
CN-120M
PRESS. SENSOR
L. TRAVEL PILOT PRESSURE
200#
49 C SIGNAL
00#
50#
CAB CHASSIS HARNESS
ZX215-1005083

E330 (abnormality in right travel pilot pressure)
User Code Service Code Reading of right travel pilot pressure is abnormal.
Trouble
Failure description
Symptom of machine Right travel speed is low. Travel deviates.

Failure of 5V
power supply
.
De al
pt
signal wire
g no
Resistance
≤1 Ω
in ti

Failure of sen-
et a

n
5
rk er
Ma t
CONTROLLER CN-121M R. TRAVEL PILOT

In
PRESS. SENSOR
201#
R. TRAVEL PILOT PRESSURE 67 C SIGNAL
00#
50#
CAB CHASSIS HARNESS
ZX215-1005084

E231 (abnormality in fuel control dial set voltage)
User Code Service Code Voltage setting of fuel control dial is abnormal. En-
Trouble
E231 31 gine returns to auto idle.
The voltage of fuel control dial other than 0.25 – 4.75V keeps more than
Failure description
Response from controller The throttle is switched to idle position.
Symptom of machine Engine returns to auto idle speed.


Failure of 5V
power supply
.
Between CN-302F ① and ③ Voltage About 5V
De al
pt
2 Open circuit
of signal wire
g n Between CN-302F ② and pin 34 of controller Resistance ≤1 Ω
3
o
of signal wire form troubleshooting.
(grounded) Between CN-302F ② and ground Resistance ≥2M Ω
in ti
Short circuit ● Turn engine start switch to OFF position. Then, keep it at ON position to
4 of signal wire perform troubleshooting.
(contact with Between CN-302F ② and ground Voltage ≤5V
et a
power supply)
n
5 Defective form troubleshooting.

rk er
knob Unplug the connector CN-302F, and measure the

Resistance 5K±15% Ω
resistance between dial ① and ③
Ma t
In
CN-142M CN-131M CN-302F

50# YELLOW
1 1 1 1
SENSOR 5V 75
506# BLUE FUEL CTRL
2 2 2 2
DIAL
55 RED
GND WIRE 3 3 0# 3 3
FUEL CONTROL DIAL

SET VOLTAGE
34
CAB
ZX215-1005085

E237 (abnormality in hydraulic oil temperature)
User Code Service Code Hydraulic oil temperature is abnormal. Only output
Trouble
E237 37 alarm is enabled.
A voltage other than 0.2 – 4.75V, transformed from hydraulic oil temperature
Failure description
that is detected by controller, keeps more than 200msec.
Only output alarm is enabled. The alarm resets automatically when conditions
become normal.

Failure of sen-
.
1
De al
sor Between CN-113M ① and ground Voltage 0.2~4.75V
pt
Open circuit of
2
g n form troubleshooting.
wire harness Between CN-113M ① and pin 31 of controller Resistance ≤1 Ω
state
Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to per-
o
3 wire harness form troubleshooting.
in ti
(grounded) Between CN-113M ① and ground Resistance ≥1M Ω

● Turn engine start switch to OFF position. Keep it at ON position to perform
Failure of 24V
4 troubleshooting.
power supply
et a
Between CN-113M ② and ground Voltage About 24V

n
5
rk er
Ma t
CN-152M
0#
In
1 1
CONTROLLER 240
2 2
HYDRAULIC OIL
CN-113M TEMP SENSOR
HYDRAULIC OIL SIGNAL
TEMP SENSOR 31 1 1
2 2 24V PWR
SUPPLY
24VPWR SUPPLY
CAB CHASSIS HARNESS
ZX215-1005086

E541 (abnormality in engine speed)
User Code Service Code Engine speed is abnormal. Only output alarm is en-
Trouble
41 E541 abled.
Failure description CPU detects out that engine speed is too low (below 100 rpm).
Only output alarm is enabled. The alarm resets automatically when conditions
become normal.

● Code 41 will be displayed on the monitor when engine start switch is

Normal condi-
1 turned from the OFF position to the ON position. This is normal as the en-
tion
.
gine is not started.
De al
pt
2 Between CN-448M ① and pin 38 of controller ≤1 Ω
wire harness Resistance
g no
Between CN-448M ② and pin 19 of controller ≤1 Ω
in ti
(grounded) Between CN-448M ① and ground Resistance ≥1M Ω

Failure of sen- form troubleshooting.
4
et a
sor Unplug the connector CN-448M, and measure the

Resistance 2.3±0.2k Ω
resistance between the speed sensors's ① and ② .
n
5
rk er
Ma t
In
CONTROLLER
ENGINE SPEED
CN-448M SENSOR
108A
ENGINE SPEED
1 SIGNAL
38
PROBING
108B
GND WIRE 19 2 GND WIRE
CAB CHASSIS HARNESS
ZX215-1005087

E450 (abnormality (a) in front pump proportional solenoid coil current)
User Code Service Code Front pump proportional solenoid coil current is ab-
Trouble
E450 50 normal. The system operates slowly.
Abnormality occurs in loaded circuit of proportional solenoid coil. Current above
Failure description
1.8A lasts for 1 second. Differential current occurs in drive protection loop.
Response from controller Stop the solenoid coil when failure is detected. Power supply must be restored.
Symptom of machine System operates slowly.

1
.
wire harness Between CN-113F ① and pin 88 of controller ≤1 Ω
De al
Resistance
Between CN-113F ② and ground ≤1 Ω
pt
g n Between CN-113F ① and wire 0# Resistance ≥1M Ω
(grounded)
o
Failure of pro- ● Turn engine start switch to OFF position. Keep it at OFF position to per-
in ti
3 portional valve Unplug the connector CN-113F, and measure the
coil Resistance 17.5 Ω
resistance between solenoid valve's ① and ②
Failure of con-
et a
4 (Except for the above reasons, the controller must be replaced in case of this
troller
failure.)
n
rk er
5
Ma t
In
CONTROLLER
SOLENOID VALVE
CN-113F (FRONT PUMP)
FRONT PUMP 702#
SOLENOID VALVE 88 1 SIGNAL
SIGNAL OUTPUT PORT
0#
CAB CHASSIS HARNESS
ZX215-1005088

E450 (abnormality (b) in front pump proportional solenoid coil current)
User Code Service Code Front pump proportional solenoid coil current is ab-
Trouble
Failure description
0.1 A lasts for 1 second. Differential current occurs in drive protection loop.

.
1
De al
Resistance
pt
g n
(grounded) Between CN-113F ① and wire 0# Resistance ≥1M Ω
o
in ti
resistance between solenoid valve's ① and ② .
et a
Failure of con-
troller
n
failure.)
rk er
5
Ma t
In
CONTROLLER
SOLENOID VALVE
CN-113F (FRONT PUMP)
FRONT PUMP 702#
SIGNAL OUTPUT PORT
0#
CAB CHASSIS HARNESS
ZX215-1005088

E451 (abnormality (a) in rear pump proportional solenoid coil current)
User Code Service Code Rear pump proportional solenoid coil current is ab-
Trouble
Failure description

1
.
De al
Resistance
pt
(grounded)
o
in ti
resistance between solenoid valve's ① and ② .
Failure of con-
et a
troller
failure.)
n
5
rk er
Ma t
In
CONTROLLER
SOLENOID VALVE
CN-114F (REAR PUMP)
REAR PUMP
702#
SIGNAL OUTPUT PORT

0#
CAB CHASSIS HARNESS
ZX215-1005089

E451 (abnormality (B) in rear pump proportional solenoid coil current)
User Code Service Code Rear pump proportional solenoid coil current is abnor-
Trouble
E451 51 mal. The system operates slowly.
Failure description

1
.
De al
Resistance
pt
(grounded)
o
in ti
Failure of con-
et a
troller
failure.)
n
5
rk er
Ma t
In
CONTROLLER
SOLENOID VALVE
CN-114F (REAR PUMP)
REAR PUMP
702#
SIGNAL OUTPUT PORT

0#
CAB CHASSIS HARNESS
ZX215-1005089

E452 (abnormality (A) in swing priority proportional solenoid coil current)
User Code Service Code Current through the proportional solenoid coil for
Trouble
E452 52 swing priority is abnormal.
Failure description
Operation of solenoid coil is stopped when failure is detected. Power supply
must be restored.

.
Open circuit of
De al
1 Between CN-133F ① and pin 98 of controller ≤1 Ω
pt
2
g n
wire harness
o
in ti
et a

Failure of con-
n
troller
failure.)
rk er
5
Ma t
In
CONTROLLER
SOLENOID VALVE
CN-133F (SWING PRIORITY)
SWING PRIORITY 608#
98 1 SIGNAL
SOLENOID VALVE
SIGNAL OUTPUT PORT

0#
CAB CHASSIS HARNESS
ZX215-1005090

E452 (abnormality (B) in swing priority proportional solenoid coil current)
Trouble
E452 52 swing priority is abnormal.
Failure description
must be restored.

.
Open circuit of
De al
pt
2
g n
wire harness
o
in ti
et a

Failure of con-
n
troller
failure.)
rk er
5
Ma t
In
CONTROLLER
SOLENOID VALVE
CN-133F (SWING PRIORITY)
SWING PRIORITY 608#
98 1 SIGNAL
SOLENOID VALVE
SIGNAL OUTPUT PORT

0#
CAB CHASSIS HARNESS
ZX215-1005090

E453 (abnormality (A) in bucket confluence proportional solenoid coil current)
User Code Service Code Current through the proportional solenoid coil for bucket
Trouble
E453 53 confluence is abnormal. Motion of bucket is slow.
Failure description
must be restored.
Symptom of machine Motion of bucket is slow.

.
Open circuit of
De al
1 Between CN-134F ① and 99 pin of controller ≤1 Ω
pt
2
g n
wire harness
o
in ti
et a

Failure of con-
n
troller
failure.)
rk er
5
Ma t
In
CONTROLLER
SOLENOID VALVE
CN-134F (BUCKET CONFLU)
BUCKET CONFLUENCE 604#
SIGNAL OUTPUT PORT

0#
CAB CHASSIS HARNESS
ZX215-1005091

E453 (abnormality (B) in bucket confluence proportional solenoid coil current)
User Code Service Code Current through the proportional solenoid coil for bucket
Trouble
E453 53 confluence is abnormal. Motion of bucket is slow.
Failure description
must be restored.
Symptom of machine Motion of bucket is slow.

.
Open circuit of
De al
pt
2
g n
wire harness
o
in ti
et a

Failure of con-
n
troller
failure.)
rk er
5
Ma t
In
CONTROLLER
SOLENOID VALVE
CN-134F (BUCKET CONFLU)
BUCKET CONFLUENCE 604#
SIGNAL OUTPUT PORT

0#
CAB CHASSIS HARNESS
ZX215-1005091

E455 (abnormality (A) in boom priority 2 proportional solenoid coil current)
Trouble
E455 55 boom priority is abnormal.
Failure description
must be restored.

.
Open circuit of
De al
pt
2
g n
wire harness
o
in ti
et a

Failure of con-
n
troller
failure.)
rk er
5
Ma t
In
CONTROLLER
SOLENOID VALVE
CN-135F (BOOM PRIORITY 2 )
BOOM PRIORITY 2 603#
SIGNAL OUTPUT PORT

GND WIRE 0#
55 2 GND WIRE
CAB CHASSIS HARNESS
ZX215-1005093

E455 (abnormality (B) in boom priority 2 proportional solenoid coil current)
Trouble
E455 55 boom priority is abnormal.
Failure description
must be restored.

.
Open circuit of
De al
pt
2
g n
wire harness
o
in ti
et a

Failure of con-
n
troller
failure.)
rk er
5
Ma t
In
CONTROLLER
SOLENOID VALVE
CN-135F (BOOM PRIORITY 2 )
BOOM PRIORITY 2 603#
SIGNAL OUTPUT PORT

GND WIRE 0#
55 2 GND WIRE
CAB CHASSIS HARNESS
ZX215-1005093

E460 (abnormality in dual speed travel solenoid valve)
User Code Service Code Connection of the solenoid coil for dual speed travel is
Trouble
60 E460 abnormal. High speed travel is not functioning.
Failure description Abnormality, open circuit or short circuit occurs in the proportional solenoid coil.
Symptom of machine High speed travel is not functioning.

.
De al
pt
Between CN-132F ① and wire 0# Resistance ≥1M Ω
g n
(grounded)
o
in ti

Failure of con-
et a
troller
failure.)
n
5
rk er
Ma t
CONTROLLER
SOLENOID VALVE
In
CN-132F (DUAL-SPEED TRAVEL)

DUAL SPEED TRAVEL 607#
SIGNAL OUTPUT PORT

0#
CAB CHASSIS HARNESS
ZX215-1005094

7.6 Troubleshooting of Electrical System (E - Mode)
Information in troubleshooting table .......................................................................................... 7-64

E-1 Engine does not start ......................................................................................................... 7-65
E-2 Engine runs rough or is unstable ....................................................................................... 7-67
E-3 Power supply of machine cannot be cut off ....................................................................... 7-68
E-4 Auto idle not functioning ..................................................................................................... 7-70
E-5 Preheating function fails..................................................................................................... 7-71
E-6 Work equipment does not work ......................................................................................... 7-72
E-7 Boom-raise speed or power is low ...................................................................................... 7-73
E-8 Arm speed or power is low ................................................................................................. 7-74
E-9 Bucket speed or power is low ............................................................................................ 7-75
.
E-10 Travel speed or power is low ........................................................................................... 7-77
De al
E-11 Blank monitor display ....................................................................................................... 7-78
pt
E-12 Monitor displays nothing .................................................................................................. 7-79
E-13 Dual speed travel not functioning..................................................................................... 7-80
g n
E-14 Incorrect engine coolant reading...................................................................................... 7-81
o
E-15 Incorrect fuel level reading ................................................................................................ 7-82
E-16 Wiper does not work ........................................................................................................ 7-83
in ti
E-17 Incorrect arm-in pilot pressure reading ............................................................................ 7-84

E-18 Incorrect arm-out pilot pressure reading .......................................................................... 7-85
et a
E-19 Incorrect boom-raise pilot pressure reading .................................................................... 7-86

E-20 Incorrect boom-lower pilot pressure reading.................................................................... 7-87
n
E-21 Incorrect bucket-curl pilot pressure reading ..................................................................... 7-88

rk er
E-22 Incorrect bucket-dump pilot pressure reading.................................................................. 7-89

E-23 Incorrect swing pilot pressure reading ............................................................................. 7-90
E-24 Incorrect left travel pilot pressure reading ........................................................................ 7-91
Ma t
E-25 Incorrect right travel pilot pressure reading...................................................................... 7-92

In

Information in troubleshooting table
● The following information is contained in the troubleshooting table and related electric circuit
diagrams. Fully understand these information before carrying out troubleshooting.
Trouble Trouble which occurs on the machine

Related information Information related to detected trouble or troubleshooting
Cause Standard value in normal state and remarks on troubleshooting

.
De al
pt
3
4
g n
Possible causes of
o
trouble (Given num- < Description >
in ti
bers are reference ● Standard value in normal state, which is used to judge possible
numbers, which do causes that might be OK or N/G.
not indicate priority) ● A reference value is used to determine OK or N/G.
et a
5
n
rk er
Ma t
In
Related circuit diagram
This is part of the circuit diagram which shows the portion where the failure occurred.
● Connector No.: A connector number Indicates a connector.
● Arrow: An arrow roughly indicates the installing location.

E-1 Engine does not start
Trouble Engine cannot be started.

Related information

● Turn engine start switch to OFF position. Keep it at OFF position to perform trou-
Low battery
1 bleshooting.
capacity Battery voltage Voltage ≥24V
Internal fail- ● Turn engine start switch to OFF position. Keep it at OFF position to perform trou-
2 ure of start bleshooting.
switch OFF position: between wire 22# and wire 11# Resistance ≥1M Ω
● Turn engine start switch to OFF position. Keep it at OFF position to perform trou-
.
bleshooting.
De al
Failure of
3
pilot switch Lockout lever FREE position: between 105 # and 27# wire ≤1 Ω
pt
Resistance
g n Lockout lever LOCKED position: between wire 105# and 27# ≥1 M Ω
● Turn engine start switch to OFF position. Keep the engine running during trouble-
shooting. (When all power supplies, grounding, signal and engine inputs are nor-
o
mal except engine output, it is the failure of start motor)
4 Failure of Engine start motor
in ti
Start switch Voltage
start motor Power supply: Terminal B and ground 20~30V
Start
Between engine input terminal S and ground 20~30V
et a
● Turn engine start switch to OFF position. Then, keep it at OFF position to perform
n

5 of wire har- Wire 21# and start motor terminal B ≤1 Ω
rk er
ness Wire 12# and start relay terminal SW Resistance ≤1 Ω

Start relay terminal L and safety relay terminal S ≤1 Ω
Failure of
Ma t
6 Battery terminal "+" (wire 20#) and control dial wire 22# Resistance ≤1 Ω
fuse F1
In
Short cir- ● Turn engine start switch to OFF position. Keep it at OFF position to perform trou-
cuit of wire bleshooting.
7 Start relay terminal SW and ground ≥1 M Ω
harness
Resistance
(grounded) Engine input terminal S and ground ≥1 M Ω
Internal ● Turn engine start switch to OFF position. Then, keep it at ON position to perform
8 failure of troubleshooting.
alternator Alternator terminal P and ground Voltage ≤1V
● Turn engine start switch to OFF position. Move it to START position when per-
forming troubleshooting.
9 Start relay Terminal SW and ground App. 24V
Voltage
Terminal S and ground App. 24V
● Turn engine start switch to OFF position. Then, keep it at ON position to perform
Failure of troubleshooting.
10
parking unit Between CN-801F 2 and 3 ≤1 Ω
Resistance
Unplug connector CN-801F; measure resistance of motor coil. App 63 Ω

START SWITCH
TERMINAL B BR ACC R1 R2 C
F1 20A 22 HEAT
20 OFF
CN-241F 21
F2 5A 10 ON
BATTERY (D-12)
START
20 22 22 13 11
1 1
10
2 2
9 9
12 12
BATTERY RELAY
21
PILOT SWITCH
1 2 3 4 5
1 2 3 4 5
.
F16 10A 105
De al
0
pt
g n LOCK RELAY
1 2 3 4 5
o
1 2 3 4 5
in ti
0
et a
22 PARK RELAY
n
CN-661F PARK MOTOR

(S-16)
64
CN-801F 64 A
rk er
10 10
9 9
63 (H-6) 22
65
B
P1
6 6 65 63
CN-161F 1 2 3 4 5
1 1
P2
E
(S-16)
0 2 2
10 10 1 2 3 4 5 0
15 15
13 3 3
Ma t
6 6
In
12a
12
14
HLR CHARGE 47
CN-613F
4
3
2
1
INDICATOR
(L-6)
4 47
3 10
2 14
1
21
12a
10
10
12a
47
14
10
SW
R
P
S
L
R
P
B
L
B
0
S
E
E
0
START RELAY SAFETY RELAY

START MOTOR ALTERNATOR
ZX215-1005095

E-2 Engine runs rough or is unstable
Trouble Engine Runs Rough or Is Unstable

Related information Engine speed can be read on the monitor.

1 Unplug the connector controller, and measure
wire harness Resistance 2.3±0.2 K Ω
the resistance between pin 19 and pin 38.
Internal failure
in sensor Between CN-448M A and B Resistance 2.3±0.2 K Ω
.
De al
pt
(grounded) Between CN-448M B and ground Resistance ≥1M Ω
Internal failure No troubleshooting can be done due to internal failure. (Failure lies in the con-
4
g n
of controller
o
troller if the reasons above are ruled out)
in ti
5
et a
n
rk er
CONTROLLER
CN-448M
（S-2） SPEED SENSOR
Ma t
SPEED SENSOR 38 A SIGNAL

INPUT SIGNAL
In
GND 19 B GND
CAB CHASSIS HARNESS
ZX215-1005096

E-3 Power supply of machine cannot be cut off
Trouble Engine cannot be stopped.

Engine stalls when start switch it turned to OFF position. There is no time
Related information
delay for power cutout.

When engine start switch is operated, if the operation of battery
Failure of bat-
1 relay contact is heard, the battery is normal. Turn the start switch
tery relay
OFF→ON→OFF.
Breakdown of form troubleshooting.
2
surge diode Between battery relay wire 20# and wire 21# Resistance ≥1M Ω
.
De al
pt
3
g no
4
in ti
et a
5
n
rk er
Ma t
In

START SWITCH
F1 20A 22 HEAT
20 OFF
CN-241F 21
F2 5A 10 ON
BATTERY (D-12)
START
20 22 22 13 11
1 1
10
2 2
9 9
12 12
BATTERY RELAY
21
PILOT SWITCH
1 2 3 4 5
1 2 3 4 5
.
F16 10A 105
De al
0
pt
g n LOCK RELAY
o
1 2 3 4 5
1 2 3 4 5
in ti
0
et a
PARK RELAY
n
22
CN-661F PARK MOTOR
(S-16)
64
CN-801F 64
rk er
A
10 10
9 9
63 (H-6) 22
65
B
P1
6 6 65 63
CN-161F 1 2 3 4 5
1 1
P2
E
(S-16)
0 2 2
10 10 1 2 3 4 5 0
15 15
13
Ma t
3 3
6 6
In
12a
12
14
HLR CHARGE 47
CN-613F
4
3
2
1
INDICATOR
(L-6)
4 47
3 10
2 14
1
21
12a
10
10
12a
47
14
10
SW
R
P
S
L
R
P
B
L
B
0
S
E
E
0
START RELAY SAFETY RELAY

START MOTOR ALTERNATOR
ZX215-1005095

E-4 Auto idle not functioning
Trouble Auto idle speed do not work

Engine speed do not decrease wen the mode is auto idle speed and grip keeps
Related information
still in "NEUTRAL" position

● Turn engine start switch to OFF position. Start the engine and keep it
Error of boom- running to perform troubleshooting.
1 Levers in NEUTRAL, pressure signal transmitted 0 KG
raise signal Pressure
Lever in operation, pressure signal transmitted 0~39 KG
Error of boom- running to perform troubleshooting.
2
.
lower signal Levers in NEUTRAL, pressure signal transmitted 0 KG
De al
Pressure
pt
Error of arm-in running to perform troubleshooting.
3
g n Levers in NEUTRAL, pressure signal transmitted 0 KG
signal
Pressure
o
in ti
Error of arm-out running to perform troubleshooting.

signal
Pressure
et a

n
Error of bucket- running to perform troubleshooting.

5
rk er
curl signal Levers in NEUTRAL, pressure signal transmitted 0 KG

Pressure
Ma t
Error of Bucket- running to perform troubleshooting.

6
dump signal Levers in NEUTRAL, pressure signal transmitted 0 KG
In
Pressure
Error of swing running to perform troubleshooting.
signal
Pressure
running to perform troubleshooting.
8 Error of travel Levers in NEUTRAL, pressure signal transmitted 0 KG
signal Pressure
Error of attach- running to perform troubleshooting.
ment signal
Pressure
Failure of con- No troubleshooting can be done for it is internal failure. (If it is not caused by
10
troller one of the factors listed above, it should be the failure of controller.)

E-5 Preheating function fails
Trouble Engine does not preheat.

Related information

Failure of pre-
1 troubleshooting.
heat fuse Between wire 21# and preheat relay pin 3# (contact) Resistance ≤1 Ω
When the preheating function is activated, if operation of the preheat relay
Failure of pre-
2 contact is heard, the relay is normal. The preheat switch is to be switched
heat relay
OFF→ON→OFF.
.
De al
troubleshooting.
Failure of pre- Turn off the preheat switch and measure the resistance
pt
3 ≥1M Ω
heat switch between wire 16# and wire 18#. Resistance
Turn on the preheat switch and measure the resistance
g no
between wire 16# and wire 18#
≤1 Ω
of wire har- troubleshooting.
in ti
4
ness (ground- Between preheat relay pin 3# (contact) and ground Resistance ≥1M Ω
ed)
et a
5
n
START SWITCH
rk er
HEAT
OFF
ON
BATTERY 20 CN-241F START

22 13 16
_ _ (D-12)
+ +
Ma t
22
1 1
20 F1 20A 22
9 9 16
In
BATTERY RELAY
1 2 3 45
PREHEAT PREHEAT RELAY
1 2 3 45
21 21
F13 160A
SWITCH CN-131M CN-142M
0
1 2 345
(D-12) (D-12) 1 2 345
18 GR-1 GLOW PLUG
7 7 6 6 17
PREHEATER
CHASSIS HARNESS CAB CHASSIS HARNESS
ZX215-1005097

E-6 Work equipment does not work
Trouble The machine is motionless while operated after starting.

Related information

running to perform troubleshooting.
Failure of lockout Item Lockout control lever Resistance
1
switch LOCK ≤1 Ω
Between wire 105# and wire 27#
FREE ≥1M Ω
state
.
≥1M Ω
De al
(grounded) Between 105# and ground Resistance
pt
Failure of coil ● Turn engine start switch to OFF position. Keep it at OFF position to per-
3 inside lockout form troubleshooting.
Between CN-136F 1 and 2 Resistance About 34 Ω
g n
solenoid valve
o
4
in ti
PILOT SWITCH
et a
CN-106F
（AMP-2）
n
F16 10A
21 27 27 105
B- 2 2
1 1
rk er
CN-161F
(S-16)
2 2
10 10
Ma t
12 12
0 105 27 606 CN-661F CN-136F
1 2 3 45 （S-16）（AMP-2）
In
1 2 3 45
1 1 1 1
8 8 2 2
PILOT SOLENOID VALVE
CAB CHASSIS HARNESS
ZX215-1005098

E-7 Boom-raise speed or power is low
Trouble Boom-raise speed or power is low.

Pilot pressure of the boom in operation can be
Related information
checked on the monitor.

● Turn engine start switch to OFF position. Start the engine and keep it run-
Failure of sen- ning to perform troubleshooting.
1 Levers in NEUTRAL, boom-raise pressure signal 0 KG
sor Pressure
Lever in operation, boom-raise pressure signal 0~39 KG
mal state
Short circuit
troubleshooting.
.
2 of harness Between harness ( from controller pin 70 to CN-126M
De al
pt
A) and ground
Open circuit of
3 troubleshooting.
g n
harness
o
Between controller pin 54 and CN-126M B Resistance ≤1 Ω
Failure of con- No troubleshooting can be done due to internal failure. (Failure lies in the con-
4
troller troller if the reasons above are ruled out)
in ti
et a
CONTROLLER
CN-126M BOOM UP
n
（DF-3） PRESS. SENSOR

BOOM UP 70 A SIGNAL
rk er
PRESSURE SENSOR
SENSOR GND WIRE 54 B GND WIRE
SENSOR 5V 56 C 5V
Ma t
In
CAB CHASSIS HARNESS
ZX215-1005099

E-8 Arm speed or power is low
Trouble Arm speed or power is low during operation.

Related information Pilot pressure of the arm in operation can be checked on the monitor.

ning to perform troubleshooting.

Failure of sen- Levers in NEUTRAL, arm-in and arm-out pressure
1 0 KG
sor signals
Pressure
Levers in operation, arm-in and dump pressure
0~39 KG
signal
.
De al
Short circuit
Between harness (from controller pin 71 to CN-
pt
2 of harness
128M A) and ground
Between harness (from controller pin 52 to CN-
g n 122M A) and ground
o
in ti
3 Between controller pin 54 and CN-128M B
harness Resistance ≤1 Ω
Between controller pin 54 and CN-122M B
Failure of con- No troubleshooting can be done due to internal failure. (Failure lies in the
et a
4
troller controller if the reasons above are ruled out)
n
rk er
CN-122M ARM-OUT
Ma t
A SIGNAL
B GND WIRE
In
C 5V
CONTROLLER
ARM-OUT ARM-IN
CN-128M
PRESS SENSOR 52 （DF-3） PRESS. SENSOR
ARM-IN
PRESS SENSOR 71 A SIGNAL
SENOSR 5V 56 C 5V
CAB CHASSIS HARNESS
ZX215-1005119

E-9 Bucket speed or power is low
Trouble Bucket speed or power is low during operation.

Related information Pilot pressure of the bucket can be checked on the monitor.

● Turn engine start switch to OFF position. Start the engine and keep it running
Failure of to perform troubleshooting.
1 Levers in NEUTRAL, bucket-curl/dump pressure signals 0 KG

sensor Pressure
Levers in operation, bucket-curl/dump pressure signals 0~39 KG
troubleshooting.
Short circuit Between harness (from controller pin 69 to CN-124M A)
.
2 of harness and ground
De al
(grounded) Between harness (from controller pin 50 to CN-127M A) Resistance ≥1M Ω
pt
g n and ground
o
3 Between controller pin 54 and CN-124M B
of harness Resistance ≤1 Ω
Between controller pin 54 and CN-127M B
in ti
Defective ● Turn engine start switch to OFF position. Keep it at OFF position to perform
bucket troubleshooting.
4 confluence
et a
About 17.5
solenoid Between CN-134F 1 and 2 Resistance
Ω
n
valve
Failure of No troubleshooting can be done due to internal failure. (Failure lies in the control-
rk er
5
controller ler if the reasons above are ruled out)
Ma t
In

CN-127M BUCKET-DUMP
PRESS. SENSOR
（DF-3）
A SIGNAL
B GND WIRE
C 5V
CONTROLLER
BUCKET-CURL CN-124M BUCKET-CURL

PRESS. SENSOR 50 （DF-3） PRESS. SENSOR
BUCKET-DUMP A SIGNAL
69
PRESS. SENSOR
.
De al
pt
5V
SENOSR 5V g n 56 C
BUCKET
CONFLUENCE SIGNAL 99
o
CN-134F BUCKET CONFLUENCE
in ti
（AMP-2） PROPORTIONAL VALVE
1 SIGNAL
et a
2
n
GND WIRE
rk er
CAB CHASSIS HARNESS

Ma t
ZX215-1005100
In

E-10 Travel speed or power is low
Trouble Travel speed or power is low during operation.

Related information Pilot pressure of travel operation can be checked on the monitor.

ning to perform troubleshooting.
Failure of sen- Levers in NEUTRAL, left and right travel pressure
1 0 KG
sor signals
Pressure
Levers in operation, left and right travel pressure
0~39 KG
signals
.
troubleshooting.
De al
Short circuit Between harness (from controller pin 49 to CN-
pt
2 of harness 120M A) and ground
(grounded) Between harness (from controller pin 67 to CN-
g n Resistance ≥1M Ω
121M A) and ground

o
3
in ti
harness Between controller pin 54 and CN-120M B Be-

Resistance ≤1 Ω
tween controller pin 54 and CN-121M B
Failure of con- No troubleshooting can be done due to internal failure. (Failure lies in the con-
4
et a
troller troller if the reasons above are ruled out)

n
rk er
CN-121M RIGHT TRAVEL

A SIGNAL
Ma t
B GND WIRE
5V
In
CONTROLLER
RIGHT TRAVEL CN-120M LEFT TRAVEL

PRESS SENSOR 67 （DF-3） PRESS. SENSOR
LEFT TRAVEL SIGNAL
49 A
PRESS SENSOR
54 GND WIRE
SENSOR GND WIRE B
56 5V
SENOSR 5V C
CAB CHASSIS HARNESS
ZX215-1005101

E-11 Blank monitor display
Trouble Monitor display is blank after the machine is powered on.

Related information


1 Failure of fuse Between wire 22# and ground About 24V
Voltage
Between wire 29# and ground About 24V
troubleshooting.
Open circuit of Between CN-7-705 pin 8 and CN-241F pin 3 ≤1 Ω
.
2
De al
wire harness Between CN-7-705 pin 9 and CN-241 pin 1 Resistance ≤1 Ω
pt
Between CN-7-705 pin 10# and ground ≤1 Ω
g n
Short circuit of troubleshooting.
Between harness (from CN-7-705 pin 8 to CN-241
o
3 wire harness ≥1M Ω
pin 3) and ground
(grounded) Between harness (from CN-7-705 pin 9 to CN-241 Resistance
in ti
≥1M Ω
pin 1) and ground
Failure of No troubleshooting can be done for it is internal failure. (If it is not caused by
4
et a
monitor one of the factors listed above, it should be the failure of monitor.)
CN-1-112
n
(D-3)
CANH
rk er
1 1
120ȍ RESISTANCE
2 2
CANL CN-7-705
CONTROLLER (D-12)
CANH
Ma t
3 3 3
CANL
MONITOR
4 4 4
29
In
CN-1-111 8 8 8
CANH 60 (D-6) 22 9 9 9
0 10 10 10
1 1
2 2 12 12 12
CANL 78 3 3 3 3
1 1 CN-241F F1 20A
(D-12) 22
F10 5A
29
20
21
PWR PWR
CAB CHASSIS HARNESS
ZX215-1005102

E-12 Monitor displays nothing
Display of monitor is illuminated but no information is

Trouble
shown on the screen after machine is powered on.
Related information

● Turn engine start switch to OFF position. Keep it at OFF position to
Failure of resis- perform troubleshooting.
1
tance Between CN-1-112 1 and 2 Resistance 120 Ω
Open circuit of perform troubleshooting.
2
.
wire harness Between CN-7-705 pin 3 and controller pin 60 ≤1 Ω
De al
Resistance
Between CN-7-705 pin 4 and controller pin 78 ≤1 Ω
pt
g n
Short circuit of
Between harness (from CN-7-705 pin 3 to con-
3 wire harness ≥1M Ω
o
troller pin 60) and ground
(grounded) Resistance
Between harness (from CN-7-705 pin 4 to control-
≥1M Ω
in ti
ler pin 78) and ground

Failure of monitor No troubleshooting can be done for it is internal failure. (If it is not one of
4
or controller the failures stated above, it should be the failure of monitor or controller.)
et a
n
CN-1-112
(D-3)
CANH
rk er
1 1
120ȍ RESISTANCE
2 2
CANL CN-7-705
CONTROLLER (D-12)
Ma t
CANH 3
3 3
CANL
MONITOR
4 4 4
In
CN-1-111 29 8 8 8
CANH 60 (D-6) 22 9 9 9
0 10 10 10
1 1
2 2 12 12 12
CANL 78 3 3 3 3
1 1 CN-241F F1 20A
(D-12) 22
F10 5A
29
20
21
PWR PWR
CAB CHASSIS HARNESS
ZX215-1005102

E-13 Dual speed travel not functioning
Trouble Only low speed travel is functioning during operation.

Related information Press the Hi/Lo button on the monitor to change travel speed.

Failure of dual ● Turn engine start switch to OFF position. Keep it at OFF position to perform
1 speed travel troubleshooting.
solenoid valve Between CN-131F A and B Resistance About 17.5 Ω
normal state

2 Between CN-132F pin A and controller pin 100 ≤1 Ω
Between CN-132F pin B and controller pin 55 ≤1 Ω
.
De al
Short circuit of
pt
troubleshooting.
3 wire harness
Between harness (from CN-132F pin A to con-
g n troller pin (100) and ground
4
o
in ti
CONTROLLER
CN-132F
et a
HIGH SPEED TRAVEL

（AMP-2） SOLENOID VALVE
n
HIGH SPEED TRAVEL 100 A SIGNAL

SOLENOID VALVE
rk er
GROUND 55 B GND WIRE

Ma t
In
CAB CHASSIS HARNESS
ZX215-1005104

E-14 Incorrect engine coolant reading
Engine coolant temperature sensor cannot correctly reflect cur-

Trouble
rent coolant temperature.
Related information Coolant temperature can be checked on the monitor.

Standard values for engine coolant temperature sensor

50°C 80 Ω
Failure of coolant 60°C 56.3 Ω
1 temperature sen- 80°C 29.5 Ω
sor 100°C 16.5 Ω
.
De al
106°C 14.3 Ω
pt
120°C 10 Ω
2
g n
Open circuit of
lead
o
Between wire 510# and controller pin 30 Resistance ≤1 Ω
in ti
Short circuit of
lead (grounded) Between wire 510# and ground Resistance ≥1M Ω
et a
Lead short to 24V

circuit
n
Wire 510# to ground Voltage ≤1V

rk er
᥻ࠊ఼
Ma t
In
510
‫⏽⎆ैދ‬ᑺӴᛳ఼ 30
偒偊ᅸ 䔺䑿㒓ᴳ
ZX215-1005105

E-15 Incorrect fuel level reading
Trouble Engine fuel level sensor cannot correctly reflect current fuel level.
Related information Fuel level can be checked on the monitor.

troubleshooting.
Fuel level sen- Pin Fuel level Resistance
1
sor error Between wire 509# and ground FULL (Upper limit) Approx. 10 Ω
EMPTY (Lower limit) 85-95 Ω
state
Open circuit of
.
2 troubleshooting.
De al
lead Between wire 509# and controller pin 11 Resistance ≤1 Ω
pt
Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to perform
3 lead (ground- troubleshooting.
ed)
g no
Between wire 509# and ground Resistance ≥1M Ω
Lead short to
4 troubleshooting.
in ti
24V Wire 509# grounded Voltage ≤1V

et a
CONTROLLER
n
rk er
FUEL LEVEL 509

SENSOR 11
Ma t
In
CAB CHASSIS HARNESS
ZX215-1005106

E-16 Wiper does not work
Trouble Wiper does not work

Related information

Internal Fail- ● Turn engine start switch to OFF position. Keep it at OFF position to perform
1 ure of wiper troubleshooting.
motor Between wiper wire 25# and ground Resistance >10 Ω
troubleshooting.
Open circuit of Between CN-241F 1 and CN-1-110 (2) ≤1 Ω
2
lead
state
Between wiper switch wire 35L# and CN-1-110 (5) Resistance ≤1 Ω
.
De al
Between wiper switch wire 35L# and CN-1-110 (4) ≤1 Ω
pt
Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to perform
troubleshooting.
g n
3 lead (ground- Harness from CN-241F 1 to CN-1-110 2 short to
ed) Resistance ≥1M Ω
ground
o
in ti
4
et a
WIPER SWITCH
n
CN-121F CN-132M CN-1-110 25

（D-12）（D-12） CN-113F （D-6）
rk er
1 1 （D-12）
F15 5A 36 2 2 36
11 3 3 35L 35L M
25 25 4 3 3
35H 35H
Ma t
4 4 4 4
CN-241M
5 5
In
（D-12）
1
21
PWR
CAB
ZX215-1005107

E-17 Incorrect arm-in pilot pressure reading
Trouble Reading of arm-in pilot pressure is incorrect.

Related information

Failure of 5V
power supply Between CN-128M ① and ③ Voltage Approx. 5V
Open circuit of
signal wire Between CN-128M ② and controller pin 71 Resistance ≤Ω
.
De al
Short circuit of form troubleshooting.
3
pt
signal wire Between CN-128M ② and ground Resistance ≥2M Ω
g n
Failure of sen-
o
sor Between CN-128M ② and ground Voltage 0.5V~ 4.5V
in ti
5
et a
n
CONTROLLER
CN-128M ARM IN
rk er
（DF-3） PRESS SENSOR

ARM IN 71 2 SIGNAL
PRESS SENSOR
55 3
Ma t
SENSOR GND WIRE GND WIRE
SENSOR 5V 75 1 5V
In
CAB CHASSIS HARNESS
ZX215-1005108

E-18 Incorrect arm-out pilot pressure reading
Trouble Reading of arm-out pilot pressure is incorrect.

Related information


Failure of 5V
power supply Between CN-122M ① and ③ Voltage About 5V
Open circuit of
signal wire Between CN-122M ② and controller pin 52 Resistance ≤1 Ω
state
.
Short circuit of
De al
signal wire
pt
Between CN-122M ② and ground Resistance ≥2M Ω
Failure of sen-
4
g n sor
Between CN-122M ② and ground Voltage 0.5V~ 4.5V
o
in ti
5
et a
CONTROLLER
n
CN-122M ARM OUT

rk er
ARM OUT
52 2 SIGNAL
PRESS SENSOR
SENSOR GND WIRE 55 3 GND WIRE
Ma t
SENSOR 5V 75 1 5V
In
CAB CHASSIS HARNESS
ZX215-1005109

E-19 Incorrect boom-raise pilot pressure reading
Trouble Incorrect Boom-Raise Pilot Pressure Reading

Related information


Failure of 5V
Open circuit of
state
.
Short circuit of
De al
signal wire
pt
Failure of sen-
4
sor
g n perform troubleshooting.
o
5
in ti
et a
CONTROLLER
n
CN-126M BOOM UP
rk er
BOOM UP 70 2 SIGNAL
PRESS SENSOR
Ma t
SENSOR 5V 75 1 5V
In
CAB CHASSIS HARNESS
ZX215-1005110

E-20 Incorrect boom-lower pilot pressure reading
Trouble Boom-Lower pilot pressure reading is incorrect.

Related information


Failure of 5V
Open circuit of
state
.
Short circuit of
De al
signal wire
pt
Failure of sen-
4
g n sor
o
5
in ti
et a
CONTROLLER
CN-125M
n
BOOM DOWN
rk er
BOOM DOWN 51 2 SIGNAL

PRESS SENSOR
55 3 GND WIRE
SENSOR GND WIRE
Ma t
SENSOR 5V 75 1 5V
In
CAB CHASSIS HARNESS
ZX215-1005111

E-21 Incorrect bucket-curl pilot pressure reading
Trouble Bucket-curl pilot pressure reading is incorrect.

Related information


Failure of 5V
Open circuit of
state
.
Short circuit of
De al
signal wire
pt
Failure of sen-
4
g n
sor
o
5
in ti
et a
CONTROLLER
n
CN-124M BUCKET CURL

rk er
BUCKET CURL SIGNAL

69 2
PRESS SENSOR
Ma t
SENSOR 5V 75 1 5V
In
CAB CHASSIS HARNESS
ZX215-1005112

E-22 Incorrect bucket-dump pilot pressure reading
Trouble Bucket-dump pilot pressure reading is incorrect.

Related information


Failure of 5V
Open circuit of
state
.
Short circuit of
De al
signal wire
pt
g n ● Turn engine start switch to OFF position. Then, keep it at ON position to
4 Failure of sensor perform troubleshooting.
o
5
in ti
et a
CONTROLLER
CN-127M BUCKET DUMP
n

rk er
BUCKET DUMP SIGNAL

50 2
PRESS SENSOR
75 1 5V
Ma t
SENSOR 5V
In
CAB CHASSIS HARNESS
ZX215-1005113

E-23 Incorrect swing pilot pressure reading
Trouble Swing pilot pressure reading is incorrect.

Related information

● Turn engine start switch to OFF position. Then, keep it at ON position

Failure of 5V
1 to perform troubleshooting.
Open circuit of
state
.
Short circuit of
De al
signal wire
pt
g n ● Turn engine start switch to OFF position. Then, keep it at ON position
4 Failure of sensor to perform troubleshooting.
o
5
in ti
et a
CONTROLLER
n
CN-123M SWING PILOT

rk er
SWING PILOT SIGNAL

PRESS SENSOR 68 2

Ma t
SENSOR 5V 75 1 5V
In
CAB CHASSIS HARNESS
ZX215-1005114

E-24 Incorrect left travel pilot pressure reading
Trouble Left Travel Pilot Pressure Reading is incorrect.

Related information


Failure of 5V
Open circuit of
state
.
Short circuit of
De al
signal wire
pt
g n ● Turn engine start switch to OFF position. Then, keep it at ON position to
4 Failure of sensor perform troubleshooting.
o
5
in ti
et a
CONTROLLER
n
CN-120M LEFT TRAVEL PILOT

（DF-3） PRESSURE SENSOR
rk er
LEFT TRAVEL PILOT 49 2 SIGNAL

PRESSURE SENSOR
Ma t
SENSOR 5V 75 1 5V
In
CAB CHASSIS HARNESS
ZX215-1005115

E-25 Incorrect right travel pilot pressure reading
Trouble Right travel pilot pressure reading is incorrect.

Related information


Failure of 5V
Open circuit of
state
.
Short circuit of
De al
signal wire
pt
Failure of sen-
4
sor
g n perform troubleshooting.
o
5
in ti
et a
CONTROLLER
n
CN-121M RIGHT TRAVEL PILOT

（DF-3） PRESSURE SENSOR
rk er
RIGHT TRAVEL PILOT 67 2 SIGNAL

PRESSURE SENSOR
55 3 GND WIRE
SENSOR GND WIRE
Ma t
SENSOR 5V 75 1 5V
In
CAB CHASSIS HARNESS
ZX215-1005116

7.7 Troubleshooting of Hydraulic and Mechanical Systems (H - Mode)
A Schematic of hydraulic system and mechanical system ........................................................ 7-94

Information contained in troubleshooting table .......................................................................... 7-96
H-1 Work equipment speed slow, or swing and travel speeds slow ......................................... 7-97
H-2 Engine speed drops sharply or engine stalls ..................................................................... 7-98
H-3 Work equipment, swing, and travel systems do not work .................................................. 7-99
H-4 Abnormal noise in hydraulic pump ................................................................................... 7-100
H-5 Auto deceleration not functioning..................................................................................... 7-101
H-6 Boom speed slow ............................................................................................................ 7-102
H-7 Arm speed slow ............................................................................................................... 7-103
H-8 Bucket speed slow ........................................................................................................... 7-104
.
H-9 Work equipment cylinders no response in separate operation ....................................... 7-105
De al
H-10 Work equipment drifts excessively ................................................................................ 7-106
pt
H-11 Work equipment moves sluggishly ............................................................................... 7-108
H-12 Other work equipment moves while single oil circuit is relieved .................................... 7-108
g n
H-13 Travel speed drops considerably while swinging and travelling .................................... 7-109
o
H-14 Machine deviates during travel ...................................................................................... 7-110
H-15 Travel speed is low .........................................................................................................7-111
in ti
H-16 Machine is not steered well or steering power is low..................................................... 7-112

H-17 Travel speed cannot be changed................................................................................... 7-113
et a
H-18 Travel system fails (only at one side)............................................................................. 7-114

H-19 Swing operation fails...................................................................................................... 7-115
n
H-20 Swing acceleration poor or swing speed low ................................................................. 7-117

rk er
H-21 Upper structure overruns remarkably when it stops swinging ....................................... 7-119
H-22 Large shock is produced when upper structure stops swinging .................................... 7-120
H-23 High noise is produced when upper structure stops swinging ....................................... 7-120
Ma t
H-24 Swing drift excessive ..................................................................................................... 7-121

In

A Schematic of hydraulic system and mechanical system
PILOT VALVE - L PILOT VALVE - TRAVEL PILOT VALVE - R
ARM SWING TRAVEL TRAVEL

BOOM BUCKET
(LEFT) (RIGHT)
LOWER
RAISE
RIGHT
BWD
OUT
DUMP
BWD
FWD
LEFT
CURL
FWD
IN
LOCK
(PILOT VALVE )
16
BOOM PRIORITY
1 2 3 4 15
5 6 7 8 9 10 11 12 BUCKET CONFLUENCE
14
.
De al
SWING PRIORITY
13
pt
VARIABLE SPEED
(TRAVEL)
ACCUMULATOR
g no
in ti
1
2
et a
3
n
19 20
rk er
Ma t
In
17 18
REGULATOR REGULATOR
SERVO SERVO
MECHANISM MECHANISM
P1 P2
M
FRONT REAR
ZX225-1105039

● The system schematic is a simplified hydraulic circuit schematic, which can be used as a ref-
erence to the hydraulic system and the mechanical system.
Sa: SAFETY VALVE

Su: SUCTION VALVE
S&S: SAFETY&SUCTION
1 BACKUP VALVE
CONFLUENCE
BUCKET
CONFLUENCE 15
ARM HOLD
1 S&S ARM VALVE

S&S 2
VALVE
REG. VALVE
1 ARM 2 VALVE
2
14
BUCKET
CYLINDER
.
De al
BUCKET S&S BUCKET 12 S&S BACKUP
S&S
10 11 VALVE S&S VALVE
BACKUP ACTUATOR
CYLINDER
pt
9
BOOM HOLD
VALVE
ANTISWING ANTISWING
BOOM
g n 9 S&S
BOOM
S&S 10
BOOM 2
9
Su
VALVE
VALVE
CYLINDER SWING
Sa
o
MOTOR
Su
VALVE
13
in ti
5 Su L. TRAVEL
VALVE
Su 6 3 SWING
VALVE 4
13
BALANCE VALVE
Sa
MECHANISM
SERVO
BALANCE VALVE
R. TRAVEL
STRT. TRAVEL 7 Su VALVE Su 8
Sa
VALVE
et a
Sa
MECHANISM
SERVO
n
Sa
TRAVEL
MOTOR (L)
rk er
TRAVEL
MOTOR (R)
1
2
Ma t
3
In
ZX225-1105040

Information contained in troubleshooting table
● The following information is contained in the troubleshooting table and related electric circuit diagrams.
Fully understand these information before carrying out troubleshooting.
Trouble Trouble which occurs on the machine

Related information Information related to detected trouble or troubleshooting

.
De al
2
pt
3 Possible causes of
g n < Description >
trouble (Given numbers
o
● Standard value in normal state, which is used to judge possible
4 are reference numbers,
causes that might be OK or N/G.
in ti
which do not indicate
● A reference value is used to determine OK or N/G.
priority)
et a
5
n
rk er
Ma t
In

H-1 Work equipment speed slow, or swing and travel speeds slow
● Work equipment speed is slow or the travel and swing speeds

Trouble
are slow.
● Set working mode to (S) and fuel control dial at position (10) to
Related information
carry out troubleshooting.

● Stop the engine. Perform troubleshooting while the engine is running at

high idle.
Defective
adjustment or Control levers Main relief pressure
1 malfunction
.
33~34.3 MPa
De al
of main relief Arm in
{337~350 kg/cm²}
pt
valve
g n If normal pressure cannot be restored after adjustment, it is possible the fail-
ure of main relief valve or internal defect. Check the valve directly.
o
Malfunction high idle.
in ti
2 of pilot relief Control levers Pilot control pressure

valve 3.9~4.1 MPa
All levers in "NEUTRAL"
{40~42 kg/cm²}
et a
Malfunction of
3 The regulator possibly fails. Check the servo mechanism of the regulator.
n
regulator
Malfunction of If the trouble is caused by other factors, it might be the main pump that has
rk er
4
main pump performance deterioration, malfunction or internal defect.
Ma t
In

H-2 Engine speed drops sharply or engine stalls
Trouble ● Engine speed drops sharply or engine stalls.

Related information ● Information concerned
1 Failure of injection pump Injection pump may be defective. Check it directly.
2 Malfunction of regulator Regulator may have malfunction. Check its servo mechanism.
Clogging of oil filter ele-
3 Oil filter element may be clogged. Check the element directly.
mal state
ment
Carbon buildup at fuel
.
4 Carbon built up at fuel injection nozzle. Check it directly.
De al
injection nozzle
pt
5 Clogging of air cleaner Air cleaner may be clogged. Check it directly.
6
g n
Abnormal wear of engine Engine may be worn abnormally. Check it directly.
o
7 Failure of oil pump Oil pump may be defective. Check it directly.
in ti
et a
n
rk er
Ma t
In

H-3 Work equipment, swing, and travel systems do not work
Trouble ● Whole work equipment, swing, and travel systems do not work.
Related information

● Stop the engine. Perform troubleshooting while the engine is run-
ning at high idle.
Malfunction of pilot Pilot lockout control lever Pilot relief pressure

1 LOCKED 0 {0}
relief solenoid valve
3.9~4.1 MPa
FREE
.
{40~42 kg/cm²}
De al
pt
ning at high idle.
Failure of relief valve
2
g n Control lever Pilot relief pressure
(pilot pump)
3.9~4.1 MPa
o
{40~42 kg/cm²}
in ti
The main pump may have malfunction or internal defect. Check it by

Failure of hydraulic following method.
3
pump ● Remove the oil pressure measurement plug and start the engine. If
et a
oil flows out of the opening, the piston pump is in good condition.
n
Internal failure of the coupling can stop rotation of the pump shaft.
Check the coupling.
rk er
4 Failure of coupling
● Loosen the oil delivery line of the pilot pump. If no oil is seen, it is
probably the failure of coupling.
Ma t
In

H-4 Abnormal noise in hydraulic pump
Trouble ● Abnormal noise is produced from the hydraulic pump

Related information ―
Low level of
1 Make a visual check.
hydraulic oil
Inferior hydrau-
2 Hydraulic oil probably contains air. Make a visual check.
lic oil
Clogging of It is probably the clogging of the vent on top of the hydraulic tank that
state
.
3 vent on top of causes negative pressure in the hydraulic tank. Press the release button of
De al
hydraulic tank the breather valve to eliminate air. Check again if the noise disappears.
pt
Clogging of
It is probably the clogging of hydraulic tank strainer that causes negative
4 hydraulic tank
g n
strainer
o
pressure in the oil suction line. Make a visual check.
Failure of main
5 The main pump may have internal defect. Check the main pump.
pump
in ti
et a
n
rk er
Ma t
In

H-5 Auto deceleration not functioning
Trouble ● Auto-deceleration is not functioning.

Related information

● Stop the engine. Perform troubleshooting while the engine is running at high
idle.
Malfunction Control levers Pilot valve output pressure
1 "NEUTRAL" 0 {0}
of sensor
3.5~4.1MPa
Operation
.
{36~42 kg/cm²}
De al
pt
● Stop the engine. Perform troubleshooting while the engine is running at high
g n idle.
Malfunction Control levers Pilot valve output pressure
2 "NEUTRAL" 0 {0}
o
of pilot valve
3.5~4.1MPa
in ti
Operation
{36~42 kg/cm²}
Failure of
3 Controller may be defective. Check it directly.
controller
et a
n
rk er
Ma t
In

H-6 Boom speed slow
Trouble ● The boom moves slowly.

Related information

● Stop the engine. Perform troubleshooting while the engine is running
at high idle.
Malfunction of right Boom control lever Pilot valve output pressure
1 pilot valve (boom "NEUTRAL" 0 {0}
circuit)
Boom RAISE ≥3.5MPa
.
De al
Boom LOWER {36 kg/cm²}
pt
Failure of pressure
2 at high idle.
sensor
g n Check the pressure sensor by replacing it with a new one.
Malfunction of boom
o
3 Spool of boom control valve may have malfunction. Check it directly.
control valve (spool)
in ti
Malfunction of boom
Retaining valve of boom control valve may have malfunction. Check the
4 control valve (re-
valve directly.
taining valve)
et a
Malfunction or de-
n
fective seal of boom

The relief valve and makeup valve in boom control valve may have mal-
5 control valve
rk er
function or defective seal. Check the valves directly.

(Relief valve and
makeup valve)
Ma t
at high idle.
In
Charge the bucket with a load of approximate 1260 kg. Cut off the oil
passage to the high-pressure side of the cylinder. Disconnect the cylin-
Failure of boom
6 der from the main valve. Measure the displacement of piston for 15 min-
cylinder
utes after the cylinder becomes stable. If the measured value is greater
than 10 mm, it is deemed that cylinder has a defective seal. For more
information on the measuring procedure refer to "Testing and Adjusting",
"Hydraulic Drift (Work Equipment) - Test".

H-7 Arm speed slow
Trouble ● The arm moves slowly.

Related information

● Stop the engine. Perform troubleshooting while the engine is
running at high idle.
Arm control lever Pilot valve output pressure
Malfunction of left pilot
1 "NEUTRAL" 0 {0}
valve (arm circuit)
≥3.5MPa
.
Arm IN or Arm OUT
De al
{36 kg/cm²}
pt
2 Failure of pressure sensor
g n running at high idle.
Check the pressure sensor by replacing it with a new one.
Malfunction of arm control
o
3 Spool of arm control valve may have malfunction. Check it directly.
valve (spool)
in ti
Malfunction of arm control Regeneration valve of arm control valve may have malfunction.
4
valve (regeneration valve) Check it directly.
Malfunction or defective
et a
seal of arm control valve The relief valve or makeup valve inside the arm control valve may
5
(Relief valve and makeup have malfunction or defective seal. Check the valves directly.
n
valve)
rk er

Cut off the oil passage to the high-pressure side of the cylinder.
Ma t
Disconnect the cylinder from the main valve. Measure the displace-
ment of piston for 15 minutes after the cylinder becomes stable. If
In
6 Failure of arm cylinder

the measured value is greater than 10 mm, it is deemed that cyl-
inder has a defective seal. For more information on the measuring
procedure refer to "Testing and Adjusting", "Hydraulic Drift (Work
Equipment) - Test".

H-8 Bucket speed slow
Trouble ● The bucket moves slowly.

Related information

at high idle.
Malfunction of right Bucket control lever Pilot valve output pressure
1 pilot valve (bucket "NEUTRAL" 0 {0}
circuit)
≥3.5MPa
.
Bucket CURL or Bucket DUMP
De al
{36 kg/cm²}
pt
Failure of pressure
2 at high idle.
sensor
g n Check the pressure sensor by replacing it with a new one.
Malfunction of
o
3 bucket control valve Spool of bucket control valve may have malfunction. Check it directly.
in ti
(spool)
Malfunction or
defective seal of
Relief valve and makeup valve in bucket control valve may have mal-
et a
4 bucket control valve

function or defective seal. Check the valves directly.
n
(relief valve and

makeup valve)
rk er

at high idle.
Charge the bucket with a load of approximate 1260 kg. Cut off the oil
Ma t
passage to the high-pressure side of the cylinder. Disconnect the cylin-

Failure of bucket
In
5 der from the main valve. Measure the displacement of piston for 15 min-
cylinder
utes after the cylinder becomes stable. If the measured value is greater
than 10 mm, it is deemed that cylinder has a defective seal. For more
information on the measuring procedure refer to "Testing and Adjusting",
"Hydraulic Drift (Work Equipment) - Test".

H-9 Work equipment cylinders no response in separate operation
● Boom cylinder gives no response in separate operation.

Trouble ● Arm cylinder gives no response in separate operation.
● Bucket cylinder gives no response in separate operation.
Related information

Work equipment control lever Pilot valve output pressure
.
1 Malfunction of pilot valve
De al
"NEUTRAL" 0 {0}
pt
≥3.5MPa
state
DIG or DUMP
{36 kg/cm²}
g n ● Stop the engine. Perform troubleshooting while the engine is
Failure of pressure sen-
o
2 running at high idle.
sor
Check the pressure sensor by replacing it with a new one.
in ti
Malfunction of control
3 Spool of control valve may have malfunction. Check it directly.
valve (spool)
et a
n
rk er
Ma t
In

H-10 Work equipment drifts excessively
Trouble (1) ● The boom drifts at excessive speed.

Related information


Charge the bucket with a load of approximate 1260 kg. Cut off the
oil passage to the high-pressure side of the cylinder. Disconnect the
1 Failure of boom cylinder cylinder from the main valve. Measure the displacement of piston
for 15 minutes after the cylinder becomes stable. If the measured
.
De al
value is greater than 10 mm, it is deemed that cylinder has a defec-
pt
tive seal. For more information on the measuring procedure refer to
"Testing and Adjusting", "Hydraulic Drift (Work Equipment) - Test".
g n
Failure of boom retain- Boom retaining valve or pilot valve may be worn or sluggish. Check
2
o
ing valve the valves.
Malfunction or defective
in ti
seal of boom control The relief valve and the makeup valve in the boom control valve
3
valve (relief valve and may have a defective seal. Check the seals.
makeup valve)
et a
Failure of boom valve

4 Spool of boom valve may be worn excessively. Check the spool.
n
spool
rk er
Ma t
In

Trouble (2) ● The arm drifts excessively.

Related information


high idle.
Cut off the oil passage to the high-pressure side of the cylinder. Disconnect
Failure of arm the cylinder from the main valve. Measure the displacement of piston for 15
1
cylinder minutes after the cylinder becomes stable. If the measured value is greater
than 10 mm, it is deemed that cylinder has a defective seal. For more infor-
mation on the measuring procedure refer to "Testing and Adjusting", "Hy-
.
draulic Drift (Work Equipment) - Test".
De al
Malfunction or Relief valve or makeup valve of the arm control valve may be defective.
pt
defective seal of Check the valves directly.
2 arm control valve ● The performance of seal can be judged by replacing it with another re-
g n
(relief valve and
o
lief valve or makeup valve. (Do not replace it with the boom-down relief
makeup valve) valve or makeup valve as their pressures are set differently.)
Failure of arm Arm retaining valve or pilot valve may be worn or sluggish. Check the
in ti
3
retaining valve valves.
Failure of arm
4 Arm valve (spool) may be worn excessively. Check it directly.
valve (spool)
et a
n
rk er
Trouble (3) ● The bucket drifts excessively.

Related information
Ma t

In

Failure of bucket at high idle.
1 Bucket control lever Leakage from bucket cylinder
cylinder
Bucket-in relief 20 ml/min
mal state
Seal of relief valve or makeup valve of bucket control valve may be defec-
Defective seal
tive. Check it directly.
of bucket control
2 ● The performance of seal can be judged by replacing it with another
valve (relief valve
relief valve or makeup valve. (Do not replace it with the boom-down
and makeup valve)
relief valve or makeup valve as their pressures are set differently.)
Defective seal
3 of bucket control Seal of bucket control valve spool may be defective. Check it directly.
valve (spool)

H-11 Work equipment moves sluggishly
Trouble ● Work equipment moves sluggishly.

Related information
Possible causes and standard value
Malfunction of arm
1 Regeneration valve of arm may have malfunction. Check it directly.
regeneration valve
in normal state
Relief valve or makeup valve of control valve may have malfunction.

Malfunction of
.
Check it directly.
De al
control valve (relief ● For arm and boom, whether a valve has malfunction can be judged
pt
2
valve and makeup by replacing it with another relief valve or makeup valve.
valve) (Do not replace it with the boom-lower relief valve or makeup valve as
g no
their pressures are set differently. )
in ti
H-12 Other work equipment moves while single oil circuit is relieved
et a
● Other work equipment moves while single oil circuit of certain work equip-
n
Trouble
ment is relieved.
rk er
Related information ● Set the working mode to (S) in order to perform troubleshooting.

Ma t
In
normal state
Defective seal of
1 Seal of control valve may be defective. Check it directly.
control valve

H-13 Travel speed drops considerably while swinging and travelling
Trouble ● Travel speed drops considerably in swinging plus travelling operation.

● If the travel speed is low in only travelling operation, check first ac-
Related information
cording to H-15.

normal state
Failure of straight The straight travel valve gives no response. Check the spool and the
1
.
travel valve logic oil circuit drain port.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

H-14 Machine deviates during travel
Trouble ● Machine deviates during travel.

Related information

Travel control lever Pilot valve output pressure
Malfunction of travel pilot
1 Forward 3.5~3.9 MPa
valve
Reverse { 36~40 kg/cm²}
.
Difference occurs between
De al
0.4 MPa {4 kg/cm²}
left and right output
pt
g n running at high idle.
Malfunction of pilot relief
2 Control lever Control circuit source pressure
valve
o
3.5~3.9 MPa
{ 36~40 kg/cm²}
in ti
3 Failure of regulator Check the regulator by swapping the front and back regulators.
Sluggishness of proportion- running at high idle.
et a
4 Travel control lever Proportional valve output pressure

al solenoid valve
n
Operate both control levers ≤0.1 MPa

rk er
Sluggishness of travel con-

5 Check the valve spool to see whether it works well.
trol valve (spool)
Internal leakage of central
6 Check it by swapping the lines.
swivel joint
Ma t

In

7 Malfunction of travel motor Travel control lever Leakage of travel motor
Travel relief 27.2 ml/min
Final drive may have internal defect. Check it directly.
● Internal defect of the final drive can be determined through
8 Failure of final drive
abnormal noise, abnormal heat, and metal powder or debris
contained in the oil drained.
Failure of travel pilot pres- Forward 3.5~3.9MPa
9
sure sensor Reverse { 36~40 kg/cm²}
Difference occurs between
0.4 MPa {4 kg/cm²}
left and right output
Check the sensor by swapping it with another one.

H-15 Travel speed is low
Trouble ● Machine travel speed is low.

Related information

ning at high idle.
Malfunction of travel
1 Forward 3.5~3.9 MPa
pilot valve
Reverse { 36~40 kg/cm²}
.
Difference occurs between left and ≤0.4 MPa
De al
right output ≤{4 kg/cm²}
pt
ning at high idle.
g n
Malfunction of pilot
2 Control lever Control circuit source pressure
o
relief valve
3.5~3.9 MPa
in ti
{ 36~40 kg/cm²}
ning at high idle.
et a
Travel speed Travel control lever Reading on monitor

n
3.5~3.9 MPa
3 Failure of sensor Lo Operated
{ 36~40 kg/cm²}
rk er
3.5~3.9 MPa
Hi Operated
{ 36~40 kg/cm²}
Ma t
Check the sensor by replacing it with another one.

In
4 Spool of travel control valve may have malfunction. Check it directly.

The makeup valve in travel control valve may have malfunction. Check
5 control valve (make-
it directly.
up valve)
Stop the engine. Perform troubleshooting while the engine is running at
Failure of travel mo- high idle.
6
tor Travel control lever Oil leakage of travel motor
● Internal defect of the final drive can be determined through abnor-
mal noise, abnormal heat, and metal powder or debris contained in
the oil drained.

H-16 Machine is not steered well or steering power is low
Trouble ● Machine is not steered well or steering power is low

Related information

Malfunction of travel pilot Travel control lever Pilot valve output pressure
1
valve Both sides in "NEUTRAL" 0 {0}
3.5~3.9 MPa
Either side operated
.
{ 36~40 kg/cm²}
De al
pt
Travel control lever Solenoid valve output pressure
g n
Malfunction of travel pilot
2 3.5~3.9 MPa
o
pressure sensor Both sides operated
{ 36~40 kg/cm²}
in ti
3.5~3.9 MPa
Either side operated
{ 36~40 kg/cm²}
Malfunction of travel Spool of travel control valve may have malfunction. Check it direct-
et a
3
control valve (spool) ly.
n
The makeup valve in travel control valve may have malfunction.
rk er
4 control valve (makeup

Check it directly.
valve)
Seal of relief valve in travel motor may be defective. Check it di-
Ma t
Failure of travel motor rectly.

5
(relief valve) ● The failure of seal can be determined by swapping the front
In
and back motors or the left and right motors.

Seal of check valve in travel motor may be defective. Check it di-
Failure of travel motor rectly.
6
(check valve) ● The failure of seal can be determined by swapping the front
and back motors or the left and right motors.

H-17 Travel speed cannot be changed
Trouble ● Travel speed cannot be changed.

Related information


ning at high idle.
Malfunction of travel Solenoid valve output
Travel speed Travel control lever
pressure
normal state
1 speed shifting solenoid

valve Lo Operated 0 {0}
.
3.5~3.9 MPa
De al
Hi Operated
{ 36~40 kg/cm²}
pt
2
g n
Failure of travel motor (in Speed shifting assembly of travel motor may have malfunction.
speed change) Check it directly.
o
in ti
et a
n
rk er
Ma t
In

H-18 Travel system fails (only at one side)
Trouble ● One side of the tracks cannot make a turn.

Related information

Defective seat of travel
Seat of makeup valve in travel control valve may have malfunction.
1 control valve (makeup
Check it directly.
valve)
Defective seat of travel Seat of relief valve in travel control valve may have malfunction.
2
motor (relief valve) Check it directly.
.
Defective seat of travel
De al
Seat of check valve in travel motor valve may have malfunction.
3 motor valve (makeup
pt
Check it directly.
valve)
g n
Speed of travel motor ning at high idle.
o
4 Travel control lever Leakage from travel motor
drops.
in ti
● Internal defect of final drive can be determined with abnormal
et a
noise, overheat, and metal powder or debris contained in the oil

drained.
n

rk er
ning at high idle.

Defective pilot pressure Forward 3.5~3.9MPa
Ma t
6
sensor Reverse { 36~40 kg/cm²}
In
Difference occurs between left and

0.4 MPa {4 kg/cm²}
right output
Check it with swapping method.

H-19 Swing operation fails
Trouble (1) ● Upper structure fails to swing in either direction.

Related information
Malfunction of swing
1 Parking brake of swing motor may have malfunction. Check it directly.

motor (parking brake)
ning at high idle.
Improper adjustment Swing control lever Swing relief pressure
.
De al
or malfunction of 25.5~28.5 MPa
2 Swing relief
pt
swing motor (relief {260~291 kg/cm²}
valve)
g n If oil pressure does not become normal after adjustment, swing motor
relief valve may have malfunction or internal defect. Check the relief
valve directly.
o
in ti
ning at high idle.

3 Failure of swing motor Swing control lever Leakage from swing motor
Swing relief ≥10 ml/min
et a
Swing mechanism may have internal defect. Check it directly.

n
Failure of swing ● Internal defect of swing mechanism can be determined with ab-
4
mechanism normal noise, overheat, and metal powder or debris contained in
rk er
the oil drained.

Ma t
In

Trouble (2) ● Upper structure only fails to swing in one direction.

Related information

ning at high idle.
Malfunction of pilot Left control lever Pilot valve output pressure
1
valve
normal state
"NEUTRAL" 0 {0}
Swing ≥3.5MPa {≥36 kg/cm²}
2 Spool of swing control valve may have malfunction. Check it directly.
.
De al
Defective seal of Seal of makeup valve in swing motor may have defect. Check it directly.
pt
3 swing motor (makeup ● Failure of the seal can be determined by swapping the right and left
makeup valves and check for any changes.
g n
valve)
o
in ti
et a
n
rk er
Ma t
In

H-20 Swing acceleration poor or swing speed low
Trouble (1) ● Swing acceleration is poor, or swing speed is low.

Related information

1 Parking brake of swing motor may have malfunction. Check it directly.
ning at high idle.
Improper adjustment Swing control lever Swing relief valve
.
De al
or malfunction of 25.5~28.5 MPa
2 Swing relief
pt
swing motor (relief {260~291 kg/cm²}
valve)
g n If oil pressure does not become normal after adjustment, swing motor
valve directly.
o
in ti
Failure of swing mo- ning at high idle.

3 Swing control lever Leakage from swing motor
tor
Swing relief ≤10 ml/min
et a
Clogging of brake
4 Disassemble, clean and check.
n
control lines
rk er
Ma t
In

● Swing acceleration is only poor on one side, or swing speed is

Trouble (2)
low.
Related information

ning at high idle.

Malfunction of pilot Swing control lever Pilot valve output pressure
1
valve "NEUTRAL" 0 {0}
Left swing
≥3.5MPa {≥36 kg/cm²}
Right swing
.
Pressure compensation valve of swing motor may have malfunction.
De al
2 motor (pressure com-
Check it directly.
pt
pensation valve)
g n Seal of makeup valve in swing motor may have defect. Check it di-
Defective seal of swing rectly.
3
motor (makeup valve) ● Swap the left and right makeup valves and observe the result in
o
order to determine whether the seal fails.
in ti

ning at high idle.
One-side leakage of
Swing control lever Pilot valve output pressure
et a
4 swing pilot pressure

"NEUTRAL" 0 {0}
sensor (shuttle valve)
n
Left swing
3.5~3.9MPa {36~40 kg/cm²}
Right swing
rk er
Ma t
In

H-21 Upper structure overruns remarkably when it stops swinging
● Upper structure overruns remarkably when it stops swinging in

Trouble (1)
both directions.
Related information

ning at high idle.
Swing control lever Swing relief pressure
Improper adjustment
25.5~28.5 MPa
1 or malfunction of swing Swing relief
mal state
{260~291 kg/cm²}
.
motor (relief valve)
De al
If oil pressure does not become normal after adjustment, swing motor
pt
valve directly.
g no
ning at high idle.
2 Failure of swing motor Control lever Leakage from swing motor
in ti
Swing relief ≤10 ml/min

et a
n
Trouble (2) ● Swing acceleration is only poor on one side, or swing speed is low.
● Set the working mode at gear (10) of power mode (S) to perform
rk er
Related information
troubleshooting.

Ma t

In

Swing control lever Pilot valve output pressure
1 Malfunction of pilot valve
"NEUTRAL" 0 {0}
mal state
Left swing
≥3.5MPa {≥36 kg/cm²}
Right swing
Malfunction of swing con- Spool of swing control valve may have malfunction. Check it direct-
2
trol valve (spool) ly.
Seal of makeup valve in swing motor may be defective. Check it
Malfunction or defec-
directly.
3 tive seal of swing motor
● Swap the left and right makeup valves and observe the result
(makeup valve)
in order to determine whether the seal fails.

H-22 Large shock is produced when upper structure stops swinging
Trouble ● Large shock is produced when upper structure stops swinging.

Related information

ning at high idle.
Malfunction of swing Swing control lever Pilot valve output pressure

1
pilot valve "NEUTRAL" 0 {0}
Left swing
state
.
≥3.5MPa {≥36 kg/cm²}
De al
Right swing
pt
Reverse prevention valve of swing motor may have malfunction.
Check it directly.
2 reverse prevention
g n
valve
● Replace the valve with a new on in order to determine whether the
valve fails.
o
3 Swing relief valve may be worn or sluggish.
in ti
relief valve
et a
H-23 High noise is produced when upper structure stops swinging

n
rk er
Trouble ● High noise is produced when upper structure stops swinging.

Related information
Ma t
In

Malfunction of back
1 Back pressure valve may have malfunction. Check it directly.
pressure valve
2 Relief valve of swing motor may have malfunction. Check it directly.
motor (relief valve)
Seal of makeup valve in swing motor may have malfunction. Check it
state
Malfunction of swing directly.

3
motor (makeup valve) ● Swap the left and right makeup valves and observe the result in
order to determine whether the seal fails.
The swing mechanism is suspected of an internal failure. Check the
inside of the machinery itself.
Failure of swing mecha-
4 ● Internal defect of swing mechanism can be determined with ab-
nism
normal noise, overheat, and metal powder or debris contained in
the oil drained.

H-24 Swing drift excessive
● Hydraulic drift of swing is large (when swing holding brake is ap-

Trouble (1)
plied).
● When swing lock switch is turned ON or when swing holding
Related information brake release switch is in normal position, swing holding brake
operates and upper structure is fixed with disc brake.
Failure of swing hold- Swing holding brake control lines and holding brake pilot valve may be
in normal state
1
ing brake control lines defective. Check them directly.
.
De al
pt
2
g n Parking brake of swing motor may have malfunction. Check it directly.
o
in ti
et a
● Hydraulic drift of swing is large (when swing holding brake is re-

Trouble (2)
n
leased).
● When swing holding brake release switch is in release position,
rk er
Related information swing holding brake is released and upper structure is secured
by only hydraulic pressure.
Ma t

In
Malfunction or defec-
Swing control valve spool may have malfunction or defective seal.
1 tive seal of swing
Check it directly.
in normal state
Failure of swing motor

2 Seal of relief valve in swing motor may be defective. Check it directly.
(relief valve)
Failure of swing motor Seal of makeup valve in swing motor may be defective. Check it di-
3
(makeup valve) rectly.

tE.
l
Pg Aona
DG
ep
in ti
etK a
n
ArkNer
Ma t
BL In

SY195/205/215/225C9 Crawler Hydraulic Excavator Disassembly and Assembly
Disassembly and Assembly
.
8 Disassembly and Assembly
De al
pt
8.1 How to Read This Manual ....................................................................................... 8-5
8.1.1 Removing and Installing an Assembly ........................................................... 8-5
g n
8.1.2 Disassembling and assembling an assembly ................................................ 8-5
o
8.1.3 Special tools................................................................................................... 8-5
in ti
8.2.1 The symbols used in this section .................................................................. 8-6

8.2 Operating Precautions ............................................................................................. 8-6
8.3 Start Motor AS - Remove and Install ..................................................................... 8-10
et a
8.3.1 Removal ....................................................................................................... 8-10

n
8.3.2 Installation .................................................................................................... 8-10

rk er
8.4 Injection Pump AS - Remove and Install ................................................................8-11

8.4.1 Removal ........................................................................................................8-11
8.4.2 Installation .................................................................................................... 8-13
Ma t
8.5 Engine Front Seal - Remove and Install ................................................................ 8-15

In
8.5.1 Removal ....................................................................................................... 8-15

8.5.2 Installation .................................................................................................... 8-15
8.6 Engine Rear Seal - Remove and Install................................................................. 8-16
8.6.1 Removal ....................................................................................................... 8-16
8.6.2 Installation .................................................................................................... 8-17
8.7 Cylinder Head AS - Remove and Install ................................................................ 8-18
8.7.1 Removal ....................................................................................................... 8-18
8.7.2 Installation .................................................................................................... 8-22
8.8 Radiator AS - Remove and Install.......................................................................... 8-24
8.8.1 Removal ....................................................................................................... 8-24
8.8.2 Installation .................................................................................................... 8-27
8.9 Engine and Hydraulic Pump AS - Remove and Install .......................................... 8-28
8.9.1 Removal ....................................................................................................... 8-28

Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator
8.9.2 Installation .................................................................................................... 8-34

8.10 Final Drive AS - Remove and Install .................................................................... 8-35
8.10.1 Removal ..................................................................................................... 8-35
8.10.2 Installation .................................................................................................. 8-36
8.11 Final Drive AS - Disassemble and Assemble ....................................................... 8-37
8.11.1 Disassembly ............................................................................................... 8-37
8.11.2 Assembly .................................................................................................... 8-41
8.12 Swing Motor and Swing Drive AS - Remove and Install ...................................... 8-46
8.12.1 Removal ..................................................................................................... 8-46
8.12.2 Installation .................................................................................................. 8-47
8.13 Swing Motor and Swing Drive AS - Disassemble and Assemble......................... 8-48
.
8.13.1 Disassembly............................................................................................... 8-48
De al
pt
8.13.2 Assembly.................................................................................................... 8-53
8.14 Idler AS - Disassemble and Assemble ................................................................. 8-58
g n
8.14.1 Disassembly............................................................................................... 8-58
o
8.14.2 Assembly.................................................................................................... 8-59
8.15 Sprocket - Remove and Install............................................................................. 8-62
in ti
8.15.1 Removal ..................................................................................................... 8-62

8.15.2 Installation .................................................................................................. 8-62
et a
8.16 Track AS - Remove and Install ............................................................................ 8-63

n
8.16.1 Removal ..................................................................................................... 8-63

8.16.2 Installation .................................................................................................. 8-65
rk er
8.17 Swing Bearing AS - Remove and Install .............................................................. 8-66

8.17.1 Removal ..................................................................................................... 8-66
Ma t
8.17.2 Installation .................................................................................................. 8-67

In
8.18 Swing Platform AS - Remove and Install ............................................................. 8-68

8.18.1 Removal ..................................................................................................... 8-68
8.18.2 Installation .................................................................................................. 8-71
8.19 Swivel Joint AS - Remove and Install .................................................................. 8-72
8.19.1 Removal ..................................................................................................... 8-72
8.19.2 Installation .................................................................................................. 8-74
8.20 Swivel Joint AS - Disassemble and Assemble ..................................................... 8-75
8.20.1 Disassembly............................................................................................... 8-75
8.20.2 Assembly.................................................................................................... 8-76
8.21 Hydraulic Tank AS - Remove and Install.............................................................. 8-77
8.21.1 Removal ..................................................................................................... 8-77
8.21.2 Installation .................................................................................................. 8-79
8.22 Control Valve AS - Remove and Install ................................................................ 8-80

8.22.1 Removal ..................................................................................................... 8-80

8.22.2 Installation .................................................................................................. 8-84
8.23 Hydraulic Pump AS - Remove and Install ............................................................ 8-85
8.23.1 Removal ..................................................................................................... 8-85
8.23.2 Installation .................................................................................................. 8-89
8.24 Middle Oil Seal (Hydraulic Pump Input Shaft)- Remove and Install .................... 8-90
8.24.1 Removal ..................................................................................................... 8-90
8.24.2 Installation .................................................................................................. 8-90
8.25 Pilot Valve AS (Work Equipment) - Disassemble and Assemble ......................... 8-91
8.25.1 Assembly.................................................................................................... 8-91
8.26 Pilot Valve AS (Travel) - Disassemble and Assemble .......................................... 8-93
.
8.26.1 Assembly.................................................................................................... 8-93
De al
pt
8.27 Hydraulic Cylinder AS - Disassemble and Assemble........................................... 8-94
8.27.1 Disassembly............................................................................................... 8-95
g n
8.27.2 Assembly.................................................................................................. 8-100
o
8.28 Work Equipment AS - Remove and Install......................................................... 8-105
8.28.1 Removal ................................................................................................... 8-105
in ti
8.28.2 Installation ................................................................................................ 8-107

8.29 Air Conditioner AS - Remove and Install............................................................ 8-108
et a
8.29.1 Removal ................................................................................................... 8-108

n
8.29.2 Installation .................................................................................................8-112

8.30 Counterweight AS - Remove and Install .............................................................8-113
rk er
8.30.1 Removal ....................................................................................................8-113

8.30.2 Installation .................................................................................................8-114
Ma t
8.31 Cab AS - Remove and Install..............................................................................8-115

In
8.31.1 Removal ....................................................................................................8-115

8.31.2 Installation .................................................................................................8-119
8.32 Cab Window Glass – Disassemble and Assemble ............................................ 8-120
8.32.1 Removal ................................................................................................... 8-121
8.32.2 Installation ................................................................................................ 8-125
8.33 Front Window AS - Disassemble and Assemble................................................ 8-138
8.33.1 Disassemble ............................................................................................ 8-138
8.33.2 Assemble ................................................................................................. 8-141
8.34 Monitor - Remove and Install ............................................................................. 8-146
8.34.1 Removal ................................................................................................... 8-146
8.34.2 Installation ................................................................................................ 8-146
8.35 Controller AS - Remove and Install.................................................................... 8-147
8.35.1 Removal ................................................................................................... 8-147

8.35.2 Installation ................................................................................................ 8-147

8.36 Radio ................................................................................................................. 8-148
8.36.1 Structure .................................................................................................. 8-148
8.36.2 Removal ................................................................................................... 8-149
8.36.3 Installation ................................................................................................ 8-150
8.36.4 Connector model and wiring .................................................................... 8-150
8.37 Battery ............................................................................................................... 8-151
8.37.1 Structure .................................................................................................. 8-151
8.37.2 Removal ................................................................................................... 8-152
8.37.3 Installation ................................................................................................ 8-153
8.37.4 Replacement ............................................................................................ 8-153
.
8.38 Start Switch........................................................................................................ 8-154
De al
pt
8.38.1 Structure ................................................................................................. 8-154
8.38.2 Removal ................................................................................................... 8-155
g n
8.39 Fuse Box............................................................................................................ 8-157
o
8.39.1 Removal ................................................................................................... 8-157
8.40 Wiper ................................................................................................................. 8-158
in ti
8.40.1 Structure .................................................................................................. 8-158

8.40.2 Working principle ..................................................................................... 8-158
et a
8.40.3 Removal ................................................................................................... 8-159

n
8.40.5 Installation ................................................................................................ 8-160

8.40.4 Angle adjustment of wiper arm................................................................. 8-160
rk er
8.41 Relay.................................................................................................................. 8-161

8.41.1 Engine relays ........................................................................................... 8-161
Ma t
8.41.2 Other relays ............................................................................................. 8-162

In
8.42 Sensor ............................................................................................................... 8-165

8.43 Connector Terminals - Insert and Remove ........................................................ 8-167
8.43.1 Insertion ................................................................................................... 8-167
8.43.2 Removal ................................................................................................... 8-168

8 DISASSEMBLY AND ASSEMBLY
8.1 How to Read This Manual
8.1.1 Removing and Installing an Assembly
Removal
● The "Removal" section contains procedure, precautions and the amount of oil or water to be
discharged.
Installation
.
De al
● Unless specified otherwise, installation of a part is a reverse procedure of removing the part.
pt
g n
8.1.2 Disassembling and assembling an assembly
o
Disassembly
in ti
● The "Disassembly" section contains procedure, precautions and the amount of oil or water to
be discharged.
et a
Assembly
n
● The "Assembly " section contains operating procedure, precautions, technical specification
rk er
and the amount of oil or water to be added.

Ma t
8.1.3 Special tools

In
● Special tools for parts disassembly and assembly are listed.
● Necessary characteristics of the tools are noted in the list of special tools.
■: Special tools that cannot be replaced and must be used.
●: Very useful tools, which can be replaced with commercially available ones.

8.1.4 The symbols used in this section
This section uses some symbols and icons that are not used elsewhere in this manual. They in-
clude:
This symbol indicates the amount of oil or water to be discharged.

This symbol indicates that specific coating agent must be used.
This symbol indicates the lubricant required.
This symbol indicates a torque specified.
This symbol indicates the amount of oil or water to be added.
This symbols indicates the weight of a component or an assembly.
.
De al
pt
8.2 Operating Precautions
g n
The following precautions must be observed before removing or installing (disassembling or as-
o
sembling) a component.
in ti
1. Precautions to be observed prior to removal operation
● Dispose the engine coolant properly if antifreeze is contained in the engine coolant.
et a
● After disconnecting a hose or tube, cover or plug must be used to prevent invasion of dirt
n
or dust.
rk er
● A suitable container must be prepared to collect oil when draining the oil.
● Matching mark must be made at where is necessary before removing in order to avoid
Ma t
mistake during reinstallation.

In
● Do not pull the wire and avoid the wire coming off. To avoid excessive force imposing on
the wire, hold the connector when disconnecting a wire.
● Tag the wires and the hoses in order to ensure their connecting positions. By doing so,
mistakes can be avoided during reinstallation.
● Count and check the number and thickness of the shims, and keep them in a safe place.
● When raising or lifting components, be sure to use proper lifting equipment of ample
strength and safety.
● When forcing screws are used to remove any components, tighten the screws evenly in
turn.
● The surrounding area must be cleaned before removing a unit. Cover the unit after remov-
al in order to prevent invasion of dirt or dust.

● Precautions to be observed when disassembling the lines
The lines disassembled must be blinded with plugs.
A: Thread-connected hoses
I.D. (mm) Code Description

Light Thread Connection
6 B210780001189 Plug
8 B210780001190 Plug
10 B210780000077 Plug
12 B210780000078 Plug
15 B210780000883 Plug
.
De al
20 B210780000079 Plug
pt
22 g n 60056667 Plug
Heavy Thread Connection
12 B210780001142 Plug
o
16 60002397 Plug
in ti
20 B210780000080 Plug
25 B210780000081 Plug
et a
B: Thread-connected adaptors (plug and nut used in combination)

n
I.D. (mm) Code Description Code Description

rk er
Light Thread Connection

6 B210780000903 Taper bore plug 23002925 Nut
Ma t
8 B210780001146 Plug B210770000011 Nut

In
10 B210780000088 Plug B210334000011 Nut

12 B210780000089 Plug B210334000012 Nut
15 B210780000882 Plug B210334000004 Nut
20 B210780000090 Plug B210334000010 Nut
22 B210780000091 Plug B210780000112 Nut
Heavy Thread Connection
12 B210780001143 Plug B210780000406 Nut
16 A820205001523 Plug B210780000405 Nut
20 B210780000902 Plug B210780000904 Nut
25 B210780001172 Plug B210334000006 Nut

2. Precautions prior to installation operation
● Tighten all the screws and nuts (sleeve nuts) to specified torques.
● Install the hoses without twisting or interference.
● Replace the gaskets, O-rings, cotter pins and lock plates with new parts.
● Bend the cotter pin or lock plate securely.
● Before applying the adhesive, clean the parts of oil and dust. Apply 2 or 3 drops of adhe-
sive to the threaded portion.
● Before applying the sealant to the gasket, clean the gasket surface of oil and dust. Check
the gasket for contamination or damage. Apply the gasket sealant evenly.
.
● Clean all parts, and correct any damage, dents, burrs, or rust.
De al
pt
● Apply engine oil to the moving parts.
g n
● Before installing a snap ring, make sure that the snap ring is mounted properly in the cir-
cular groove.
o
● Before connecting the wiring connector, clean the wiring connector of oil, dirt or water.
in ti
Make sure that the wiring connector is connected securely.
● Before using an eyebolt, check the eyebolt for deformation or deterioration. Screw on the
et a
eyebolt as far as possible and align it to the direction of the hook.

n
● Before tightening the split flange, tighten it evenly in turn in order to prevent over tighten-
ing on one side.
rk er
NOTE: After reassembling the hydraulic cylinder, main pump or other hydraulic equipment
that has been disassembled and repaired, it is necessary to bleed the air from the hydraulic
Ma t
cylinder prior to initial operation of the cylinder. The purging procedure is performed as the
following:
In
1) Start the engine and run the engine at low idle.
2) Operate the work equipment control lever in order to cycle the movement of the hydraulic
cylinder 4 or 5 times. Hold the cylinder at where it is 100 mm from its stroke end.
3) Go on operating the hydraulic cylinder 3 or 4 times to its stroke end.
4) You can run the engine at normal speed after this operation.
NOTE: This procedure is to be performed before using your machine for the first time after
repair or long storage.

3. Precautions to be observed upon completion of the operations
● Completely discharge the engine coolant, tighten the drain valve, and add coolant to the
specified level. Run the engine to circulate the coolant through the system. Check the
coolant level again.
● Add hydraulic oil to the specified level after disassembly and reinstallation of a hydraulic
unit. Run the engine to circulate the hydraulic oil through the system. Check the oil level
again.
● Bleed the air from the system after removing and repairing the lines or hydraulic unit and
reassembling the parts.
For more information, see “Air in Each Component - Bleed” on page 6-46.
.
● Add the specified amount of grease (molybdenum disulphide) to the work equipment re-
De al
lated parts.
pt
g no
in ti
et a
n
rk er
Ma t
In

8.3 Start Motor AS - Remove and Install
8.3.1 Removal
CAUTION
● Before removing the start motor assem-
bly, disconnect the cable from the nega-
tive (-) post of the battery, and insulate
between the cable and the negative post
with insulation tape.
1. Open the engine hood.
.
De al
2. Disconnect the cables (1), (2), (3), (4) and
pt
(5). g n
3. Unscrew the bolts (6) and (7) used to fix Starter
the start motor. Remove the start motor as-
o
Terminal B
sembly.
in ti
et a
Terminal S
n
rk er
Starter relay
ZX215-1006001
Ma t
In
8.3.2 Installation
● Installation is to be performed in the re- 1 2 3 4 6

verse order of removal.
Terminal B locknut (start motor):
18 ~ 25 N·m {1.8 ~ 2.6 kgf·m}
Fixing bolts (start motor):
43±6 N·m {4.4±0.6 kgf·m}

5
7
ZX215T-1006002

8.4 Injection Pump AS - Remove and Install
8.4.1 Removal
CAUTION
● Disconnect the negative (-) post of the
battery.
.
De al
pt
g n ZX215T-1006003
o
2. Disconnect the air intake hose (1).
in ti
1
et a
n
rk er
Ma t
In
ZX215T-1006004
3. Disconnect fuel supply tube (2), fuel deliv-

ery hose (4), fuel return hose (3) and fuel
supply tube (5). 5
● Block the hose with a cork in order to
prevent flow of fuel from the hose.
4 ZX215T-1006005

4. Disconnect the lubrication tube (6).
ZX215T-1006006
.
De al
5. Disconnect six fuel delivery tubes (7).
pt
7
g no
in ti
et a
n
ZX215T-1006007
rk er
6. Disconnect the air hose (8).

Ma t
7. Remove the bolt (9) fixing the electronic

8
In
choke. Disconnect the bolt (10) fixing the

governor motor.
10
ZX215T-1006008

8. Adjust the injection timing of the timing

gear. For more information, see “Fuel In-
jection Timing - Test and Adjust” on page 6-13.
9. Remove the injection pump mounting nuts

in order to disassemble the injection pump
assembly.
A: 4 nuts on the flange B
B: 1 nut A
ZX215-1006009
.
De al
pt
8.4.2 Installation
g n
● Installation is to be performed in the re-
o
in ti
Bolts for installation of fuel supply

tube:
20~29 N·m {2.1~3.0 kgf·m}

et a
Relief valve:
n
rk er
20~29 N·m {2.1~3.0 kgf·m}
Bolts for installation of engine oil line:

Ma t
10~13 N·m {1.0~1.3 kgf·m}

In
Fuel injection tube:
24 N·m {2.5 kgf·m}
Bolts for installation air hose:
12~15 N·m {1.2~1.5 kgf·m}
● Adjust the engine speed. For more in-

formation, see “Engine Speed - Test
and Calibrate” on page 6-3.

● Installation of the fuel injection pump is to

be performed as the following:
1) Check the fuel injection timing to see if it

has been adjusted properly.
● For more information, see “Fuel Injec-

tion Timing - Test and Adjust” on page 6-13.
2) Assemble the fuel injection pump assem-

bly and tighten the 4 nuts at position A and
1 nut at position B. B
Nut: 9.8±2 N·m {10±0.2 kgf·m} A
.
● Air bleeding
De al
pt
ZX215-1006009
Bleed the air from the fuel injection system.
g no
in ti
et a
n
rk er
Ma t
In

8.5 Engine Front Seal - Remove and Install
8.5.1 Removal
1. Remove the radiator assembly.
For more information, see “Radiator AS -

Remove and Install” on page 8-24.
Water pump
2. Remove the engine fan (1), the belt (2) and
the pulley (3). 3
1
.
De al
2
pt
g n ZX215-1006010
3. Remove the mounting nut (4) and replace

o
the cone (5) and the O-ring (6). Remove
in ti
the crankshaft belt pulley (7).

et a
n
6
rk er
Ta 4
7
Ma t
5 ZX215-1006011
In
4. Disassemble the front oil seal (8).
8.5.2 Installation
● Installation is to be performed in the re- 8

ZX215-1006012
Nut: 490 N·m {50 kgf·m}

8.6 Engine Rear Seal - Remove and Install
8.6.1 Removal
1. Remove the hydraulic pump assembly.
For more information, see “Hydraulic Pump

AS - Remove and Install” on page 8-85.
2. Remove the bolt (1), the latch piece (2)

and the bearing (3).
3. Remove the flywheel (4). 5
3
4. Remove the engine speed sensor (5) and 6
.
De al
Ta 1
the flywheel shell (6).
pt
2 4
g n ZX215-1006013
o
5. Remove the rear seal (7).
in ti
et a
n
rk er
Ma t
7
In
ZX215-1006014

8.6.2 Installation
● The installation is to be performed in the

reverse order of removal.
Bolt:
39 N·m {4.0 kgf·m} + 47° Sealant
● The rear oil seal is to be installed accord-

ing to the following procedure:
ø2mm
1. Apply engine oil to the lips of the rear seal.
2. Clean the oil-sealing surface.
.
De al
3. Apply the sealant evenly and continuously Line
pt
align the line of the rear seal. ZX215-1006015
Sealant (Tonsun 1596)

g n
4. The installation is to be performed 3 min-
o
utes after application of the sealant. Be
in ti
careful not to deviate the line while apply-

ing the sealant.
et a
n
rk er
Ma t
In

8.7 Cylinder Head AS - Remove and Install
8.7.1 Removal
CAUTION
● Disconnect the negative (-) post of the
battery.
1. Drain the engine of coolant.
Coolant: 18 L
.
De al
pt
ZX215T-1006016
g no
in ti
1
et a
n
rk er
Ma t
In
ZX215T-1006017
4. Remove piping (2) and piping (3) between

the fuel filter and the injection pump.
ZX215T-1006018

5. Remove the fuel filter bracket (4) and the

fuel filter assembly (5).
6. Remove the six delivery hoses (6).
ZX215T-1006019
.
De al
7. Remove the exhaust muffler connector
pt
cover (7). 6
g no
in ti
et a
n
rk er
ZX215T-1006020
8. Remove the air cleaner suction hose (8).

Ma t
9
9. Remove the air intake tube (9) and its
In
clamps (10) between the turbocharger and 7 10

the intercooler.
10. Remove the engine oil delivery tube (11)

and the oil return tube (12).
8
ZX215T-1006021

11. Remove the turbocharger assembly.
11
12
ZX215-1006022
.
De al
pt
12. Remove the exhaust manifold (13). 13
g no
in ti
et a
n
rk er
ZX215-1006023
Ma t
13. Remove the radiator inlet hose (14) and

In
outlet hose (15).

14
15
ZX215T-1006024

14. Remove the six nozzle seats (16).
16
ZX215T-1006025
.
De al
15. Remove the rocker arm housing (17).
pt
17
16. Remove the rocker arm assembly (18).
g n
17. Remove the pushrod (19).
o
18. Remove the 25 mounting bolts from the
in ti
18
cylinder head assembly. Lift the cylinder
head assembly in order to disassemble it.
et a
19. Remove the cylinder head gasket (21). 19

20
n
rk er
Ma t
21
In
ZX215-1006026

8.7.2 Installation
● The installation is to be performed in the

reverse order of removal.
Installation of cylinder head gasket
Choose a cylinder head gasket as per the

following.
1. Measure the amount of piston projection of

each cylinder.
2. Select from the following table a gasket
.
with a thickness suitable for the maximum
De al
piston projection after measurement. In ad-
pt
dition, even if one cylinder's piston projec-
tion is 0.05 mm greater than the average,
g n
the gasket with a thickness one grader
o
higher (A→B, B→C) is to be used.
in ti
Unit: mm
Piston Projection Cylinder Head Gasket Size mark

A B C
et a
Thickness
Average Size
Tightened
n
0.546~0.610 A 1.3
rk er
0.610~0.674 B 1.35
0.674~0.738 C 1.4
“UP”
Ma t
3. The size of cylinder head gasket is deter-

mined according the notch.
In
4. Install the cylinder head gasket to the

crankshaft case as indicated by the arrow.
Notch
NOTICE ZX215-1006027
The amount of piston projection must be

measured as the amount of piston projec-
tion may vary when replacing a piston or
connecting rod.

Bolt (rocker cover installation):
4.9~6.9 N·m {0.5~0.7 kgf·m}
Bolt (cylinder head):
147 N·m {15 kgf·m}+90°
Bolt threads (cylinder head):
Engine oil
Tappet circumference:
Engine oil
Tappet ends:
.
De al
pt
Engine oil
● Adjustment of valve clearance

g n
F o r m o r e i n f o r m a t i o n , s e e “ Va l v e
o
Clearance - Adjust” on page 6-8.
in ti
● Adding coolant
Add engine coolant to the specified level.

et a
Start the engine to circulate the coolant in

order to release all foams. Check the cool-
n
ant level again.

rk er
Ma t
In

8.8 Radiator AS - Remove and Install
8.8.1 Removal
2. Open the pressure cap (1). Open the drain

valve to discharge engine coolant from the
coolant tank.
Coolant: approx. 18 L
1 Cover plate
3. Remove the coverplate.
.
De al
pt
g n ZX215T-1006028
o
4. Remove the two U-bolts (2).
in ti
5. Disconnect the hydraulic oil cooler inlet

connector (3) and outlet connector (4).
Block the openings to prevent leakage of 3
et a
hydraulic oil.
n
6. Discharge hydraulic oil from the hydraulic

cooler.
rk er
Hydraulic oil radiator: approx. 5.6 L

2
Ma t
7. Disconnect the coolant tank hose (5). 4

ZX215T-1006029
In
8. Disconnect the cooler inlet hose (6) and

outlet hose (7).
ZX215T-1006030

9. Disconnect the intercooler air inlet tube (8)

and outlet tube (9).
6
7 ZX215T-1006031
.
De al
10. Remove the four bolts (10) from the air
pt
conditioner radiator. Remove the air condi-
tioner radiator and store it properly.
g no
10
in ti
10
et a
n
ZX215T-1006032
rk er
11. Remove the radiator fan guard (11).

Ma t
In
11
ZX215T-1006033

12. Remove the four mounting bolts (12) from

the radiator bottom and the two mounting 13
bolts (13) from the left and right brackets.
12
ZX215T-1006034
.
De al
13. Mount the hoisting bolts (14) to both sides
pt
of the radiator in order to hoist the radiator
assembly.
g n
NOTE: Before the radiator assembly is
o
hoisted, move the radiator assembly axially
in ti
until the fan avoids its guard.

et a
14
n
rk er
ZX215T-1006035
Ma t
In

8.8.2 Installation

NOTE:
● Adjust the clearance (a) between the fan

and the fan guard in order to have a uni-
form clearance surrounding the fan.
● Check the values (a) at the four measuring

points in the left, right, top and bottom di-
rections, which should be as the following:
.
Standard clearance (a) in all directions:
De al
15±1.5 mm
pt
Fan diameter (b): ø620 mm
g n
Fan guard inner diameter (c): ø650 mm
o
● Engine coolant and hydraulic oil adding
in ti
Add a specific amount of coolant and

hydraulic oil. Start the engine to circulate
et a
the coolant and hydraulic oil. Check the

coolant level and the oil level.
n
Engine coolant: approx. 18 L

rk er
Hydraulic oil radiator: approx. 12 L

Ma t
In

8.9 Engine and Hydraulic Pump AS - Remove and Install
8.9.1 Removal
CAUTION
ground. Stop the engine. Disconnect
the cable from the battery negative (-)
post.
● Loosen the butterfly nut on the breather

.
De al
lieve internal pressure.
pt
NOTE: Mark the lines to avoid mistakes during
reinstallation.
g no
1. Remove the hydraulic tank suction filter el-
ement and block the opening.
in ti
2. Drain the engine of coolant.
Coolant: approx. 18 L
et a

n
rk er
ZX215T-1006028
Ma t
In
4. Disconnect piping (1), (2) and (3).
3
2
ZX215T-1006036

5. Disconnect piping (4), (5) and (6).

5
6. Remove the sensors (7) and (8).
6
8
ZX215T-1006037
.
De al
7. Remove the clamps (9) and (10). Remove
pt
the line (11) and the cable (12).
g no
11
9
in ti
10
et a
n
rk er
12
Ma t
ZX215T-1006038
In
8. Unscrew the connection bolt (13) of the

governor motor and the connection bolt (14) 15
of the engine stopper.
9. Disconnect the external cable from the 14

starter (15).
10. Remove the mounting bolt (16) from the 13

hose clamp.
16
ZX215T-1006039

11. Disconnect the cables (17) and (18) as

well as the tubes (19) and (20) from the 18 20
compressor. 17
19
ZX215T-1006040
.
De al
12. Disconnect the hoses (21), (22), (23) and
pt
(24) between the engine and the radiator
g n 24
o
in ti
21
et a
22
n
23 ZX215T-1006041
rk er

Ma t
In
25
ZX215T-1006042

14. Disconnect the external cable (26) of the

rpm sensor.
15. Disconnect the external cable (27) of en-

gine oil pressure sensor.
26 27
ZX215T-1006043
.
De al
16. Disconnect the engine oil inlet tube (28)
pt
and outlet tube (29).
30
g n
17. Disconnect the wiring (30) of the engine oil
o
pressure switch.
29
in ti
28
et a
n
rk er
ZX215T-1006044
Ma t
18. Disconnect the cables (31) and (32), and

remove the hose clamp (33).
In
33
32
31
ZX215T-1006045

19. Remove the hose clamp (35).
20. Disconnect the wiring (34) of the water

temperature sensor.
35
34
ZX215T-1006046
.
De al
21. Disconnect the cables (36) and (37) of the
pt
water temperature switch.
g n 37
o
in ti
36
et a
n
rk er
ZX215T-1006047
22. Disconnect the oil return hose (38).

Ma t
23. Disconnect the A/C water pipe (39).

In
38
39
ZX215T-1006048

24. Disconnect the radiator fan guard (40).
40
ZX215T-1006049
.
De al
25. Remove the fixing bolt (41) on each of the
pt
four mounting plates of the damper. Lift the
engine and main pump assembly.
g no
Engine and hydraulic pump AS:
in ti
640 kg
et a
41
n
41
ZX215T-1006050
rk er
Ma t
In

8.9.2 Installation

● Open the radiator tank cover to add cool-

ant. Also add coolant to the coolant reser-
voir.
Engine coolant: approx. 22.5 L.

● Refill the hydraulic tank with hydraulic oil.
.
De al
Hydraulic tank: approx. 225 L
pt
● Start the engine to circulate the coolant
in order release the foams, and check
g n
the coolant level again.
o
● Start the engine to circulate the hy-
in ti
draulic oil in the hydraulic system, and

check the oil level again.
● Air bleeding
et a
For more information, see “Air in Each

n
Component - Bleed” on page 6-46.

rk er
Ma t
In

8.10 Final Drive AS - Remove and Install
8.10.1 Removal
CAUTION
ground. Stop the engine. Operate the
breather valve to release internal pres-
sure.
1. Remove the sprocket.
.
De al
For more information, see “Sprocket -
pt
Remove and Install” on page 8-62.
2. Remove the motor cover plate (1).

g no
in ti
et a
1
ZX215-1006051
n
rk er
3. Disconnect the four hoses (2) of the travel

motor and the corresponding hose connec- 2
Ma t
tors.
In
ZX215T-1006052

4. Remove the 30 mounting bolts from the

final drive assembly (3), and lift the assem-
bly for disassembling.
3
Final Drive Assembly: 250 kg
NOTICE
● Be careful not to damage the surface
of mounting seal installed on the hose
base.
ZX215-1006053
● Never use the threaded holes to lift the
.
cover when lifting the final drive.
De al
pt
8.10.2 Installation
g no
in ti
Mounting bolts (final drive assembly):

et a
245~309 N·m {25~31 kgf·m}

n
rk er
● Hydraulic oil adding
Add hydraulic oil through the filler opening

to the specified level. Start the engine to
Ma t
circulate oil in the hydraulic system, and

In
● Air bleeding


8.11 Final Drive AS - Disassemble and Assemble
8.11.1 Disassembly
1. Oil draining
Open the drain plug to drain the oil from

the final drive tank.
Final drive tank: approx. 4.7 L

2. Cover
Remove the bolts. Use eyebolts ① to the

cover (1).
.
De al
①
pt
g no
in ti
1
et a
ZX215-1006054
n
rk er
3. Spacer
2
Remove the spacer (2).
Ma t
In
ZX215-1006055

4. No. 1 planetary carrier assembly
1) Remove the No.1 planetary carrier as- 3

sembly (3).
ZX215-1006056
.
De al
2) Disassembly of No.1 planetary carrier
pt
assembly.
g n
3) Remove the screws (4). Remove the 9 7 4 5 10 8
coverplate (5) from the planetary carrier
o
assembly (6).
in ti
4) Remove the thrust washer (7), gear (8),

bearing (9), bearing inner race (10) and
a second thrust washer (11).
et a
11
6
n
ZX215-1006057
rk er
5. No.1 sun gear shaft 12

Ma t
Remove No.1 sun gear shaft (12).

In
ZX215-1006058

6. Thrust washer 13 14
Remove the thrust washer (13).
7. No.2 sun gear
Remove No.2 sun gear (14).
ZX215-1006059
.
De al
pt
8. Disassembly of No.2 planetary carrier
assembly g n 18 19 15
1) Remove the screws (15). Remove the 16

o
plate (16) and the planetary gear (17)
17
from the carrier assembly (22).
in ti
20
2) Remove the bearing inner race (19) 23
21
and outer race (18). Remove the plate
et a
(20). 22
n
3) Remove the screw (21) to take the

planetary carrier assembly (22) and the
rk er
ZX215-1006060
shim (23) from the body.
Ma t
9. Hub assembly
In
②
1) Use eyebolts to remove the hub as-
sembly (24) from the travel motor.
24
ZX215-1006061

2) Disassemble the hub assembly as the

following.
26 27
3) Remove the float seal (25).
4) Remove the bearing (26) and bearing

(27) from the hub (28).
NOTE: Do not damage the bearing retainer

when removing the bearing (26).
25 28
ZX215-1006062
.
De al
5) Remove the float seal (29) from the
pt
travel motor.
g no
29
in ti
et a
n
30
ZX215-1006063
rk er
Ma t
In

8.11.2 Assembly
NOTE: Clean all the parts. Check that these

parts are free from any contamination or dam-
age. Apply some engine oil to the sliding sur- 26 27
face prior to installation.
1. Hub assembly
1) Install the bearing 26 and bearing (27)

by pressing them onto the hub (28).
2) Install the float seal (25).

25 28
.
De al
ZX215-1006062
pt
g n
● Remove any oil or dust from the O-ring
or O-ring contact surface. Dry the parts
o
before installing the float seal.
in ti
● After installing the float seal, check that

the angle of the floating seal is within 1
mm.
et a
● Apply a thin layer of engine oil to the

n
sliding surface after the float seal has

rk er
been installed.
ZX215-1006064
Ma t
In
3) Install the float seal (29) to the travel

motor (30).
● See the above step 2 for the installation

procedure.
29
30
ZX215-1006063

4) Use eyebolts ② to carefully place the

hub assembly (24) onto the travel mo- ②
tor. Tap to press fit the bearing.
24
ZX215-1006061
.
De al
pt
2. Calculation of shim thickness
g n
1) Measure the thickness (H) of the raised
part of No.2 carrier assembly (22).
o
22
in ti
H
et a
n
rk er
ZX215-1006065
Ma t
2) Measurement of raised thickness

In
Apply 3000 Kg load to the bearing and

measure the value (H) of the raised
part of the bearing.
● Turn the hub 2-3 times before applying Load 3000Kg

a pushing force.
h
● Do not use a spray gun to cushion the

bearing.
● Do not push or strike the resin retainer.

ZX215-1006066
3) Shim thickness calculation: C=H-h.

4) Place the shims on the body and insert

the dowel pin. Press the carrier assem-
bly onto the dowel pin and tighten it
with screw (21). Apply locking adhesive
Tensiometer
to the threads.
Screw-locking adhesive:
(Tonsan 1277)
Screw (21):
ZX215-1006067
539±28 N·m {55±2.9 kgf·m}
● Use a tensiometer to measure the tan-
.
gential force of hub to motor rotation.
De al
pt
Tangential force: Max.294 N {30 kg}
Maximum tangential force occurs when

g n
the rotating direction begins to change.
o
in ti
3. Assembly of No.2 planetary carrier as-

sembly 18 19 15
et a
1) Assemble the No.2 planetary carrier

n
16
assembly according to the following
17
rk er
procedure.
20
NOTE: Replace the plates (20) and (16) 23
21
with new parts.
Ma t
22
In
2) Assemble the bearing (18) and bearing

(19) to the gear (17). Assemble the top
and bottom plates (16) and (20), and ZX215-1006060
place the gear assembly into the carrier
assembly (22).
3) Tighten the screw (15).
Screw (15):
539±28 N·m {55±2.9 kgf·m}
● Check the flexibility of gear (17) after

assembling the planetary carrier as-
sembly.

4. Thrust washer 13 14
Install the thrust washer (13).
5. No.2 sun gear
Install No.2 sun gear (14).
ZX215-1006059
.
De al
pt
6. No. 1 sun gear shaft 12
Install No.1 sun gear shaft (12).
g no
in ti
et a
n
rk er
ZX215-1006058
Ma t
7. No.1 planetary carrier assembly

In
1) No. 1 planetary carrier assembly is as-

sembled as the following. 9 7 4 5 10 8
NOTE: Replace the thrust washers (7)

and (11) with new parts.
2) Assemble the bearings (9) and (10)

onto the gear (8). Assemble the top
and bottom thrust washers (7) and (11). 11
Place the gear assembly into the car- 6
rier assembly (6). ZX215-1006057
3) Fix the coverplate (5) to the carrier as-

sembly (6) with screw (4).

4) Install No.1 planetary carrier assembly

(3).
3
ZX215-1006056
.
De al
8. Spacer
pt
2
Install the spacer (2).
g no
in ti
et a
n
ZX215-1006055
rk er
9. Cover
Ma t
Use eyebolts to assemble the cover (1).

In
Use a torque spanner to tighten the bolts.
Bolts:
73.4±3.63 N·m {7.5±0.4 kgf·m} Torque wrench
10. Oil adding
Tighten the drain plug and add engine oil

through the filler.
ZX215-1006068
Final drive case: approx. 4.7 L

● Check the oil level after the final drive
has been successfully installed to the
chassis.

8.12 Swing Motor and Swing Drive AS - Remove and Install
8.12.1 Removal
CAUTION
ground. Stop the engine. Press the re-
lease button of the breather valve to re-
lease residual pressure in the hydraulic
tank. Place the hydraulic lockout con-
trol in the LOCK position.
.
Release the residual pressure in the hy-
De al
draulic circuit. Refer to “Residual Pressure
pt
in Hydraulic Circuit - Release” on page 6-40.
g n
1. Disconnect the hoses (1) to (7).
o
● Between hydraulic tank and swing motor 3
(port DR)
in ti
● Between central swivel joint and swing mo-

tor (port DR)
et a
● Between swing motor and main valve (port

n
M) 5
7
rk er
● Between swing motor and main valve (port 6

4 1 2
HA)
ZXT225-1106002
● Between swing motor and main valve (port

Ma t
HB)
In
● Between swing motor and main valve Px

port (port SH)
8
● Between swing motor and solenoid valve
block (port PG) 9
2. Remove the 11 fixing bolts (8).
3. Lift the swing motor and swing drive as-

sembly (9) for disassembling.
NOTE: Slowly lift the swing motor and

swing drive assembly in order to avoid
damaging the hoses and other parts. ZXT225-1106003
Swing motor and swing drive as-

sembly: 260 kg

8.12.2 Installation
● Installation is performed in the reverse or-

der of removal.
Mounting bolts (swing motor and

swing drive assembly):
490~608 N·m {50~62 kgf·m}

.
De al
pt
● Air bleeding
g n
o
in ti
et a
n
rk er
Ma t
In

8.13 Swing Motor and Swing Drive AS - Disassemble and Assemble
8.13.1 Disassembly
1. Draining of oil
Open the drain plug to drain the oil from

the swing drive.
Swing drive: approx. 4.4 L

2. Swing motor assembly
1) Place the swing motor and swing drive
.
assembly on a suitable cribbing. Be 1
De al
careful not to damage the drive gear or
pt
let it contact the ground.
g n
2) Unscrew the 14 bolts in order to re-
move the swing motor assembly (1).
o
in ti
Swing motor assembly: 70 kg

et a
n
ZX225-1006077
rk er
3. No.1 sun gear

2
Ma t
1) Remove No.1 sun gear (2).

In
ZX215-1006072


3 4
1) Remove No.1 carrier assembly (3) and
the plate (4).
.
De al
pt
ZX215-1006073
g no
2) Disassemble the carrier assembly.
in ti
Cut the rivets on the shaft (8) to re-

move the shaft (8), and remove in turn 6 7 8 9
5
et a
the gear (6), bearing (9) and plate (7).

n
rk er
ZX215-1006074
Ma t
In
5. Ring gear
10
Unscrew the mounting bolts to remove the
ring gear (10).
ZX215-1006075

6. No. 2 sun gear

11
Remove No. 2 sun gear (11).
.
De al
pt
g n ZX215-1006076
o
in ti
12
1) Remove No.2 carrier assembly (12).
2) Disassemble No. 2 carrier assembly as

et a

n
rk er
Ma t
In
ZX215-1006077

3) Insert pin (13) and push the shaft (14)

out of the carrier assembly (19).
NOTE: Pull out the pin (13) after re-

moval of the shaft. 19 16 15 18
4) Remove the thrust washer (16), gear 17

(17) and a second thrust washer (19).
14
5) Insert the pin (15) to remove the bear-
ing (18) from the shaft. Remove the pin 13
(15).
ZX215-1006078
.
De al
pt
8. Snap ring 20
Remove the snap ring (20).

g no
in ti
et a
n
rk er
ZX215-1006079
Ma t
9. Disassembly of main shaft

In
Press 21 22
1) Place the shaft housing assembly on a
press and push the shaft assembly (21)
out of the shaft housing assembly (22).
ZX215-1006080

2) Disassemble the shaft assembly in the

Press
following procedure.
Remove the bearing (23) from the shaft

(24).
23
24
.
ZX215-1006081
De al
pt
g n
10. Bearing
o
26
27
Remove the bearing (25) and the oil seal
in ti
(26) from the housing (27).

et a
n
rk er
Ma t
25 ZX215-1006082
In

8.13.2 Assembly
NOTE: Clean all the parts and check for any

23
contamination or damage. Apply engine oil to
the sliding surface of the parts.
1. Bearing
Press the bearing (23) into the housing

(27).
.
De al
27 ZX215-1006083
pt
2. Oil seal
g no
27 26
Press the oil seal (26) into the housing (27).
in ti
Oil seal installation surface:
Gasket sealant (Loctite 515)

et a
n
rk er
ZX215-1006084
Ma t
In
3. Housing assembly
24
1) Position the plate (28) on the shaft (24).
2) Position the housing assembly (22) on

the shaft (24). Press in the bearing.
22
28
ZX215-1006085

4. Bearing
22 25
Press in the bearing (25).
● When press fitting the bearing, press

the bearing inner race and outer race
simultaneously. Never press only the
inner race.
● After assembling the bearing, check if

the housing rotates freely.
ZX215-1006086
.
De al
pt
5. No. 2 Planetary carrier assembly
1) Reassemble No. 2 carrier assembly ac-

g n
cording to the following procedure.
o
19 16 15
2) Assemble the plate (16) in the carrier 18
in ti
assembly (19).
17
3) Assemble the gear (17) in the carrier
14
et a
assembly (19). Put the bearing (18)

on the shaft (14). Slightly tap the pin
n
13
(15) into the bore after alignment. Use
rk er
a rubber hammer to tap the pin. Make

sure that the pin (15) must not higher ZX215-1006078
than the bearing (18).

Ma t
4) Push the shaft assembly into the car-

In
rier assembly (19). Be careful not to

damage the gear and the plate. Align
the pin bore of the shaft with that of
the carrier assembly, and install the pin
(13). Carefully tap the pin with a rubber
hammer during installation.
NOTE: Installation of the shaft requires

rotating the planetary gear. Be careful not
to damage the thrust washer.

6. Assemble in turn the snap ring (20),

No.2 carrier assembly and No.2 sun No.2 planetary carrier 11 20
gear (11).
.
ZX215-1006087
De al
pt
g n
7. Installation of ring gear
o
10
Apply sealant on the mating surface

indicated by (C) and tighten it with screws.
in ti
Never get the sealant onto the ring gear c

(10).
et a
Mating surface:
n
Sealant (Loctite 515)

rk er
Ma t
In
ZX215-1006088
8. No. 1 planetary carrier assembly
1) No. 1 carrier assembly is assembled as

2) Install the plate (7) into the carrier as- 6 7 8 9

sembly (5). 5
3) Install the gear (6) onto the plate after

installing the bearing (9) into the gear.
4) Press the shaft (8) into the gear (6) and

ZX215-1006074
the carrier assembly (5). Rivet one end
of the shaft.
● Check if the gear rotates freely.

5) Install No. 1 carrier assembly (3) and

3 4
the plate (4).
.
De al
pt
ZX215-1006073
g no
in ti
9. No. 1 sun gear assembly 2
Install No. 1 sun gear (2).

et a
n
rk er
Ma t
In
ZX215-1006072

10. Installation of swing motor assembly
Apply sealant to the contact surfaces of the

ring gear and the motor cover, and install
the swing motor assembly.
Contact surface:
Sealant (Loctite 515)
Swing motor assembly: 55 kg

Mounting bolts (swing motor):
156±5 N·m {16±0.5 kg}
.
NOTE: The 14 bolt holes of the swing
De al
motor and swing drive assembly are
pt
distributed nonuniformly. The mating direc-
tion of each hole is fixed, as shown in the
g n
illustration on the right. The installation of
o
swing motor requires proper alignment of
the bolt holes in order to ensure the instal-
in ti
lation orientation.
et a
n
11. Lubricant adding

rk er
Screw on the drain plug and add lubricant

through the filler to the specified level (the
upper mark of oil stick).
Ma t
In
Swing drive: approx. 4 L

ZX215-1006089

8.14 Idler AS - Disassemble and Assemble
8.14.1 Disassembly
7
8
1. Remove the dowel pin (1) and the support 6
(2). 13
12
10
2. Remove the float seals (3) from the sup- 5
port (2) and the idler (4).
3. Remove the O-ring (11). Remove the idler

(4) from the shaft (5) and the support as- 9
sembly (7). 11
3
1
.
NOTE: The idler contains 80 ml oil, which
De al
should be drained completely before disas-
pt
sembling. Spread a cloth on the floor to
prevent smearing the floor with oil.
g n 4
2 ZX215-1006090
o
in ti
4. Remove the float seals (6) on the other

4 6
side from the idler (4), shaft (5) and sup-
port assembly (7). 5
et a
n
rk er
Ma t
6 7
In
ZX215-1006091
5. Remove the dowel pin (8) in order to re-

move the support (7) from the shaft (5).
5
6. Remove the bushings (9) and (10) from the 9，10 4
idler (4).
7 8
ZX215-1006092

8.14.2 Assembly
1. Install the bushings (9) and (10) in the idler

(4).
9 10 4
ZX215-1006093
.
De al
pt
2. Assemble the O-ring. Install the support (7)
to the shaft (5) with the dowel pin (8).
g n 5
9，10 4
o
in ti
et a
n
7 8
rk er
ZX215-1006092
Ma t
3. Install the float seals (6) to the idler (4),

In
shaft (5) and support (7) assembly.
● Float seals
Completely remove the grease from the 6

contact surfaces (hatched area in the
illustration on the right) of O-ring and
float seal before installing the float seal.
In addition, care must be taken to keep
the contact surface of float seal free
from dust.
ZX215-1006094

● After installation of the float seals,

check that the sealing inclination should
be less than 1 mm and the seal protru-
sion between 5 and 7 mm. a
ZX215-1006095
.
4. Install the shaft (5) and support (7) assem-
De al
bly to the idler (4). 5
pt
7
4
g no
in ti
et a
ZX215-1006096
n
rk er
Ma t
In

5. Install the float seal (3) to the idler (4) and

support (2).
4 3
NOTE: Apply oil to the sliding surface of 2 3
float seal. Care must be taken to keep the
sliding surface from any contaminants or
dust.
NOTE: Remove the oil and dust from the

contact surfaces of the O-ring and float
seal. ZX215-1006097
.
De al
pt
g n 3
o
in ti
ZX215-1006098
et a
n
6. Install the O-ring. Install the support (2)

rk er
7
with the dowel pin (1). 8
6
7. Add oil and screw on the plug. 13
12
10
Ma t
5
In
Oil: approx.
80 ml (No.18 hyperbola gear oil)
Plug: 9
11
3
205.8±49 N·m {21±5 kgf·m} 1
4
2 ZX215-1006090

8.15 Sprocket - Remove and Install
8.15.1 Removal
1. Remove the track assembly.
Refer to “Track AS - Remove and Install”

on page 8-63.
1
2. Swing the work equipment 90°and lift the
chassis with the work equipment. Place a
block between the track frame and the
track shoe.
①
.
3. Remove the sprocket (1).
De al
pt
Sprocket: 58 kg
g no
ZX215-1006099
in ti
et a
8.15.2 Installation
n

rk er
Threads (bolt - sprocket):

Ma t
Thread sealant (Tonsan 1277)

In
Bolts (sprocket):
339±20 N·m {35±2 kgf·m}

8.16 Track AS - Remove and Install
Special tools
Mark Part Name Necessity Qty

Manual/electric hydraulic
M track removing/installing ● 1
machine
8.16.1 Removal
1. Choose a place that has enough space to
.
spread the track. Park the machine when
De al
the master pin is between the idler and the
pt
carrier roller.
g n
2. Lower the work equipment. Loosen the
o
grease fitting (1) and release the track ten-
sion.
in ti
WARNING 1
et a
● The adjustment cylinder is under ex-

ZX215T-1006100
tremely high pressure. Never loosen the
n
grease fitting by more than one turn.

rk er
3. Pull out the master pin (2) with the tool (M).
Ma t
2
In
ZX215-1006101

4. Remove the tool (M). Move the machine

forward so that the temporary pin is in
front of the idler. Place the block .
5. Remove the temporary pin and the dust

seal. Move the machine backward to 3
②
spread the track (3).
ZX215-1006102
.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

8.16.2 Installation
● Installation is to be performed in the re- Corner

Track shoe nut
verse order of removal. (Square)
For more information, see “Track Tension - R

Test and Adjust” on page 6-24. Corner R
● Installation procedure of track shoe bolts Corner

R
and nuts
1. Bring the R side of the track shoe nut (1) Seat surface
to the link seat surface. Both seat surfaces in close contact
should be in close contact when assem-
bling the track shoe.
.
De al
NOTE: If the track shoe bolts are installed
pt
from the other side, the corner of nut will
interfere with the link seat surface, causing
g n ZX215-1006103
the nut to raise and the bolt to loosen.
o
2. Tighten the bolts of track shoe to the
in ti
torque below.
Track shoe bolts:

et a
750±30 N·m {77±3 kgf·m}

n
rk er
● Use the tool (M) to press the master pin.

Make sure that the protrusion of master pin
Ma t
meets the size (a).

In
Master pin protrusion (a): 2.5±1 mm
● Before installing the dust seal, apply a

grease (No.2 lithium base) to its contact
surface with the bushing.
ZX215-1006104

8.17 Swing Bearing AS - Remove and Install
8.17.1 Removal
1. Remove the swing platform assembly.
For more information, see “Swing Platform

2. Dismount the 36 bolts (1) to remove the

swing bearing assembly.
.
De al
pt
g no
1
in ti
ZX215T-1006105
et a
3. Hoist the swing bearing assembly (2).

n
Swing bearing assembly: 314 kg

rk er
2
Ma t
In
ZX215T-1006106

8.17.2 Installation

Threads (bolt - swing bearing):
Thread adhesive (Tonsun 1277)
Mounting bolts (swing bearing):
Step 1:
Use a pneumatic spanner to tighten the

bolts.
.
De al
Step 2:
pt
Torque to: 549±59 N·m {56±6kgf·m}
g n
1) When a torque spanner is used to tighten
the bolts, tighten first the four corners and
o
mark them.
in ti
2) Other bolts will be tightened clockwise or

counterclockwise. After one bolt is tight-
ened, tighten the next one on the diagonal
et a
position and make a mark.

n
3) Tighten the rest bolts in this way.

rk er
● Let the S mark in the soft zone of the

inner race of the inner ring face the
Ma t
right side, as shown in the photo, and

install the swing bearing to the track
In
frame.
● Apply grease to the inside of the gear

ring of the swing bearing.
NOTE: All gear teeth must be covered

by grease .
Inner race soft zone
Swing bearing:
Grease(supramoly lithium base):15 L
ZX215T-1006107

8.18 Swing Platform AS - Remove and Install
8.18.1 Removal
CAUTION
● Fully extend the arm and the bucket.
Lower the work equipment to the
ground and move the hydraulic lockout
control lever to the LOCK position.
1. Disassemble the work equipment assem-
.
bly.
De al
pt
For more information, see “Work
Equipment AS - Remove and Install” on
g n
page 8-105.
o
2. Remove the counterweight assembly.
1
in ti
For more information, see “Counterweight

et a
3. Remove the four hoses (1) of boom cylin-

ZX215T-1006108
der.
n
NOTE: Plug the hoses to prevent flow of

rk er
oil.
Ma t
In
4. Lift the boom cylinder assembly (2).
ZX215T-1006109

5. Remove the plate (3) and the pin (4). Lift

the boom cylinder assembly (2) in order to
remove it. 4
● Remove the boom cylinder assembly
on the other side in the same way.
Boom cylinder AS: 230 kg
ZX215T-1006110
.
De al
6. Remove the plate (5), air intake hose (6)
pt
and fan guard (7).
g n
NOTE: Removal of the swing platform
requires removing other parts that interfere 5
o
with the lifting of swing platform.
in ti
6
et a
7
n
ZX215T-1006111
rk er
7. Disconnect the six hoses above the swivel

joint assembly.
Ma t
● Central swivel joint (port A) - Left travel

control valve (port BTL)
In
● Central swivel joint (port C) - Left travel

control valve (port ATL)
● Central swivel joint (port F) - Solenoid

valve
10 11
● Central swivel joint (port G) - Swing 9
motor (port T) 12
8
● Central swivel joint (port D) - Right trav- 13
el control valve (port ATR) 14 ZX215T-1006112
● Central swivel joint (port B) - Right trav-

el control valve (port BTR)
8. Remove the bolt (14).

9. Unscrew the 32 swing platform mounting

bolts in order to remove the swing platform 15
assembly (15). Lift the swing platform as-
sembly off the machine.
NOTE: Remove the front and rear mount-

ing bolts of the platform. Use a lever block
to adjust the swing platform so that the
platform can reach a balance both longi-
tudinally and laterally. Remove the last two
bolts finally.
NOTICE
.
ZX215T-1006113
De al
● Be careful not to impact the central
pt
swivel joint while removing the swing
platform assembly.g no
Swing platform assembly:
in ti
Swing Platform
Assembly
Only (Ref.)
8,427 kg 1,689 kg
et a
n
rk er
Ma t
In

8.18.2 Installation

Clamping screws (air intake hose):
5.4~6.4 N·m {0.55~0.65 kgf·m}
Mating surface (swing bearing):
Flat surface sealant (Tonsun 1596)
Threads (bolt - swing platform):
.
Thread adhesive: (Tonsun 1277)
De al
pt
Mounting bolts (swing platform):
g n
Step 1: Tighten the bolts with a pneumatic
spanner.
o
Step 2: tighten them again.
in ti
490~608 N·m {50~62 kgf·m}

et a
n

rk er
Add through the filler opening the hydraulic

oil to the specified level. Start the engine
to circulate oil in the hydraulic system, and
Ma t

In
● Air bleeding
Bleed the air from the travel motor.


8.19 Swivel Joint AS - Remove and Install
8.19.1 Removal
WARNING
● Release residual pressure in the hy-
draulic circuit before disconnecting the
hydraulic hoses.
Refer to “Residual Pressure in Hydraulic Cir-

cuit - Release” on page 6-40.
.
NOTE: Tag each line so as to ensure correc-
De al
tion installation.
pt
g n
1. Disconnect the six hoses from (1) to (6) on
the central swivel joint of the travel motor.
o
4
1) Central swivel joint (port T) - Left travel
in ti
motor (port T) 3 5
2) Central swivel joint (port T) - Right trav-

et a
el motor (port T) 6
n
3) Central swivel joint (port B) - Left travel

2 1
motor (port PA)
rk er
4) Central swivel joint (port D) - Right trav-

ZX215T-1006114
el motor (port PB)
Ma t
5) Central swivel joint (port A) - Left travel

In
motor (port PB)
6) Central swivel joint (port C) - Right trav-

el motor (port PA)

2. Disconnect the eight hoses from (7) to (14).

10
7) Central swivel joint (port F) - Left travel 9
motor (port P)
13
8) Central swivel joint (port F) - Right trav-
el motor (port P)
7
9) Central swivel joint (port G) - Swing
11 12
motor (port T) 8
10) Central swivel joint (port F) - Solenoid 14

valve 15
ZX215T-1006115
11) Central swivel joint (port C) - Left travel
.
control valve (port ATL)
De al
pt
12) Central swivel joint (port A) - Left travel
control valve (port BTL)
g n
13) Central swivel joint (port D) - Right trav-
o
el control valve (port ATR)
in ti
14) Central swivel joint (port B) - Right trav-

el control valve (port BTR)
et a
3. Remove the fixing bolt (15).

n
4. Remove the four mounting bolts (16).

rk er
16
ZX215T-1006116
Ma t
5. Remove the six mounting bolts (17) from

In
the transition plate. Remove the swivel

joint assembly (18).
18
Central swivel joint: 56 kg
Transition plate
16
17
ZX215-1006117

8.19.2 Installation

verse order of removal. BD
NOTE: Install the central swivel joint facing

the direction indicated in the illustration.
Central swivel joint
Sprocket
● Oil adding (hydraulic tank)
Add through the filler opening the hydraulic

oil to the specified level. Start the engine
.
to circulate oil in the hydraulic system, and AC
De al
ZX215-1006118
pt
● Air bleeding g n
Bleed the air from the travel motor.
o
in ti

et a
n
rk er
Ma t
In

8.20 Swivel Joint AS - Disassemble and Assemble
8.20.1 Disassembly
1. Remove the bolt (1) and the spring washer

1
(2).
2
2. Remove the cover (3). 3
4
3. Remove the gasket (4), O-ring (5) and 5
snap ring (6). 6
7
4. Remove the rotor (13) from the housing (9).
8
NOTE: Be careful not to damage the slid-
.
De al
ing surface of the seal of the rotor (13).
9
pt
5. Remove the spacer (7) and the gasket (8)
from the housing (9).
g n 10
6. Remove the dust seal (12) from the swing
o
shaft (13).
11
in ti
7. Remove the O-ring seal (11) and the seals 12

(10) from the housing (9).
et a
n
13
rk er
ZX215-1006119
Ma t
In
ZX215-1006120

8.20.2 Assembly
1. Install the dust seal (12) on the rotor (13).
NOTE: Let the lip face the housing while

Dust seal
installing the dust seal.
2. Install the six seals (10) in the housing (9).

Lip
3. Fix the rotor (13) on a work bench. Install
the housing (9) on the rotor (13).
NOTE: Since the clearance between Body
the housing (9) and the rotor (13) is ap-

ZX215-1006121
proximately 0.1 mm, install the housing (9)
.
on the rotor (13) slowly and vertically. Be
De al
careful not to damage the seals (10) and
pt
the O-ring seal (11).
g n
4. Use a rubber hammer to tap the housing (9)
o
in order to match the rotor (13) properly.
in ti
5. Install the spacer (7) and gasket (8) in the
housing (9).
6. Install the gasket (4), O-ring seal (5) and

et a
snap ring (6) on the rotor (13).

n
7. Install the cover (3). Tighten the bolts (1)

rk er
and the spring washer (2).
Fixing bolts: 49 N·m{5 kgf·m}

Ma t
In

8.21 Hydraulic Tank AS - Remove and Install
8.21.1 Removal
1. Drain the hydraulic oil into a suitable

container for storage or disposal.
1
Hydraulic oil: approx. 225 L
2 5 4
2. Open the engine hood. 3
3. Remove the engine hood (1), cover (2) and
control valve cover (3).
4. Remove the cover mounting frame (4) and
.
De al
the screen (5).
pt
g n ZX215T-1006122
o
5. Remove the screen (6) and the partition
in ti
frame mounting bolt (7) on the hydraulic 6 7

tank side.
6. Remove the screw (8) and the fuel control

et a
motor (9).
n
rk er
8
Ma t
9
ZX215T-1006123
In
7. Remove the two oil return hoses (10) from

the hydraulic tank.
10
ZX215T-1006124

8. Disconnect the seven hoses.
● (11): Oil return - pilot T block
● (12): Oil return - main pump

17
● (13): Oil return D2 - main valve
● (14): Sensor - temperature

18
● (15): Oil return - solenoid valve 15 11
● (16): Oil return D1/D3 - main valve 12
13
16 14
● (17): Oil return - swing motor ZX215T-1006125
NOTE:
.
De al
pt
● Disconnect the oil inlet hose (18) from the
hydraulic tank after disconnection of the oil
g n
inlet tube from the pump.
o
● Attach each hose with an identification tag.
in ti
● Use a sleeve nut to prevent the fitting and

the cone seal from damage. 19
9. Remove the hose clamp (19).
et a
n
rk er
ZXT225-1106008
Ma t
10. Lift the hydraulic tank assembly and re-

In
move the six bolts (20).
11. Lift off the hydraulic tank assembly for dis-

assembling.
20
Hydraulic tank assembly: 130 kg
ZX215T-1006127

8.21.2 Installation

Screw
Drain plug (hydraulic tank):
58.8~78.5 N·m {6.0~8.0 kgf·m}
NOTE: After tightening the hose clamping Up

screw, check that the screw should be in Down
the range indicated in the illustration.
Screw (hose clamp):

ZX215-1006128
.
8.8±0.5 N·m {0.9±0.05 kgf·m}
De al
pt
● Install the hose clamp and tighten the
screw according to the illustration on
g n
the right. Pipe Clamp Hose
o
Bolt:
in ti
245.2~308.9 N·m {25~31.5 kgf·m}

et a

n
Bulge
rk er
ZX215-1006129
Ma t
● Air bleeding
In


8.22 Control Valve AS - Remove and Install
8.22.1 Removal
WARNING
ground. Stop the engine. Press the re-
lease button of the breather valve to re-
lease residual pressure in the hydraulic 1
tank. Place the hydraulic lockout con-
trol in the LOCK position. 2
.
De al
pt
tion installation.
g no
ZXT225-1106009
in ti
1. Lift the hood (1).
2. Remove the cover (2) above the control

valve.
et a
n
3. Remove the engine silencing hood (3).

rk er
3
Ma t
ZXT225-1106010
In
4. Remove the baffle (4) to (9) of the pres-

sure transducer and tag them.
(4): XAK Bucket DIG
(5): XBb1 Boom DOWN 7

4
8
(6): XAtL Travel LEFT 5
(7): XBa1 Arm IN 9
6
(8): XBs Swing RIGHT
(9): XAtr Travel RIGHT ZXT225-1106011

5. Disconnect the pilot hoses (10) to (18) and

tag them properly. 10 11 12 13 14
(10): XBtr Travel RIGHT
(11): XAs Swing LEFT

18
(12): PSP Swing priority
(13): XAa1 Arm OUT

15
16
(14): XBp2 Bucket confluence 17
(15): XBtL Travel LEFT ZXT225-1106012
(16): XAb1 Boom UP
.
De al
(17): XBK Bucket DIG
pt
(18): XAa2 Arm OUT
g no
6. Remove the port (19) (accumulator to
solenoid valve), port (10) (pilot filter to ac-
in ti
cumulator). Remove hose clip (21) of the

central swivel joint.
et a
n
rk er
21
19 20
Ma t
ZXT225-1106013
In
7. Remove bucket hoses (22) and (23) and

seal the ports.
8. Remove arm hoses (24) and (25) and seal

the ports.
9. Remove boom hoses (26) and (27) and

seal the ports.
22 24 25 23
26
27 ZXT225-1106014

10. Remove central swivel joint hoses (28),

(29), (30) and (31). Remove travel speed 32
switching hose (32) and seal the ports.
30
29
28 31
ZXT225-1106015
.
De al
11. Remove swing motor hoses (33) and (34).
pt
Remove swing motor oil complement hose
(35). Seal the ports properly. 33
g no
35
34
in ti
et a
n
ZXT225-1106016
rk er
12. Remove pipe (36) (main valve to radiator).

Ma t
In
36
ZXT225-1106017

13. Remove pipe (37) (main valve to return oil

tank). Seal the ports properly.
37
ZXT225-1106018
.
De al
14. Remove hydraulic pump hoses (38) and
pt
(39). g no
in ti
et a
38 39
n
ZXT225-1106019
rk er
15. Remove hoses (40) to (44) on the solenoid

Ma t
valve and tag them properly.

In
(40): PPC lockout valve
(41): Main valve PnA2
(42): Main valve XBP2
(43): Main valve PSP
(44): Travel PT port

40 41 42 43 44
WXT215-1208001G

16. Remove the fixing bolts (45). Lift the con-

trol valve assembly (46) for disassembling.
Control valve assembly: 220 kg
45
45
46
ZXT225-1106021
.
De al
pt
8.22.2 Installation
g no
in ti

et a

n

rk er
● Air bleeding
Ma t
Bleed the air from the circuit between the

In
valve and the hydraulic cylinder.


8.23 Hydraulic Pump AS - Remove and Install
8.23.1 Removal
WARNING
ground and stop the engine. Press the
release button of the breather valve to
release residual pressure in the hydrau-
lic tank.
● Disconnect the cable from the negative
.
(-) post of the battery before performing
De al
the job.
pt
g n
tion installation.
o
1. Remove the oil inlet filter element from the
in ti
hydraulic tank and stop oil outflow with an

oil stopper.
et a
NOTE: If no oil stopper is used, remove

Oil stopper
the drain plug and drain the oil from the
n
hydraulic tank and from circuits.

rk er
Hydraulic tank: Approx. 225 L

ZX215-1006144
2. Lift the hood (1).
Ma t
In
ZX215T-1006145

3. Remove the pin (2) and the bolts (3). Lift

the engine hood in order to remove it.
2
ZX215T-1006146
.
De al
pt
4. Remove the right upper cover (4).
4
g no
in ti
3
et a
n
rk er
ZX215T-1006147
Ma t
In
5. Disconnect the hose (5) supplying oil to the

lower proportional valve and the hose (6)
delivering oil from the pilot pump.
5 6
ZX215T-1006148

6. Disconnect the shutdown wire (7).
7
ZX215T-1006149
.
De al
7. Remove the right door (8).
pt
8. Remove the hydraulic pump cover (9).
g no
in ti
8
et a
n
9
rk er
ZX215T-1006150
Ma t
9. Disconnect the oil drain hose (10) and seal

10
the openings properly.
In
10. Disconnect the high-pressure hoses (11)

and (12) connecting to the control valve,
and seal the openings properly.
11. Disconnect the harness (13) of the pres- 12

sure transducer. 11
12. Disconnect the pilot pump oil inlet hose (14) 13

and seal the openings properly. 14
15
13. Disconnect the pilot pump oil inlet tube (15) ZX215T-1006151
and seal the openings properly.

14. Disconnect the solenoid valve harnesses

(16) and (17). Remove the cable straps (18)
and (19).
16 18 19 17
ZX215T-1006152
.
De al
pt
15. Remove the four bolts (20) of the hydraulic
g n
pump. Lift the hydraulic pump assembly
(21) to remove it.
o
21
in ti
Hydraulic pump assembly: 112 kg
20
et a
n
rk er
ZX215T-1006153
Ma t
In

8.23.2 Installation

Screw
NOTE: After tightening the hose clamping
screw, check that the screw should be in
the range indicated in the illustration.
Screw (hose clamp): Up

Down
8.8±0.5 N·m {0.9±0.05 kgf·m}
ZX215-1006128
.
De al
pt
● Install the hose clamp and tighten the
screw according to the illustration on
g n Pipe Clamp Hose
the right.
o
Mating surface (hydraulic pump
housing):
in ti
Gasket sealant: (Loctite 515)

et a
Bulge
n
ZX215-1006129
rk er

Ma t

In
Hydraulic tank: approx. 225 L

● Air bleeding


8.24 Middle Oil Seal (Hydraulic Pump Input Shaft)- Remove and Install
8.24.1 Removal
1. Remove the hydraulic pump assembly (1).
For more information, see “Hydraulic Pump 1

2
2. Remove the screw (2). Remove the bear- 3
ing cover (3). 4
3. Pry the oil seal (4) out with a screwdriver.
NOTE: Be careful not to damage the shaft
.
De al
while prying the oil seal.
pt
g n ZX215-1006154
o
in ti
8.24.2 Installation
et a

n
4
rk er
Seal lip:
Grease (No.1 Calcium base grease)

Ma t
Seal circumference:
In
● Apply a thin layer of grease to the oil

seal circumference.
ZX215-1006155

8.25 Pilot Valve AS (Work Equipment) - Disassemble and Assemble
NOTE: This section discusses only the precautions when reassembling the work equipment pilot
valve assembly.
8 9
1 2 3 4 5 6 7 10
.
De al
pt
ZX215T-1006156
8.25.1 Assembly
g no
● Reassembly of the work equipment pilot Plug (5) circumference:
in ti
valve assembly
1. Install the plate (9) in the valve body (8)
with O-ring seal. Tighten the socket bolt
et a
U-joint moving surface:

(10).
n

Socket bolt:
rk er
25~33 N·m {2.55~3.36 kgf·m} Threads in valve body:
2. Insert the spring (7) into the spool hole in Thread adhesive (Tonsun 1277)
Ma t
the valve body (8). Put the spool (6) in the

In
spring. Install the plunger (5) on the spool.

Push the plug (5) to the spool hole.
3. Install the plate (4) on the plunger (5).

Tighten the U-joint (3).
4. Install the plate (2). Align the position of the

plate (2) and tighten the nut (1).
Nut: 98~133 N·m {10~13.5 kgf·m}
NOTE: Location of each oil port is stamped

on the bottom of valve body.

● A p p l y t h e t h r e a d a d h e s i v e ( To n -
5~7 mm
sun 1277) to two points on the inner
threads. The amount of application is
approximately 0.02 g.
U-joint (3):
98~133 N·m {10~13.5 kgf·m}
NOTE: Tightening is to be made to the

specified torque. ZX215-1006157
Contact surface between plung-

er (5) and plate (2):
.
Grease 0.3~0.8 ml (No.1 Calcium base
De al
grease)
pt
g no
in ti
et a
n
rk er
Ma t
In

8.26 Pilot Valve AS (Travel) - Disassemble and Assemble
NOTE: This section discusses only the precautions when reassembling the travel pilot valve as-
sembly.
᥼ᴚ
.
De al
pt
9
g no
8 7 6 4 3 2 1
5
in ti
ZX215T-1006158
et a
8.26.1 Assembly
n
● Reassembly of the pedal pilot valve assembly

rk er
1. Install the spring (8) into the spool installation hole in the body assembly (9). Install the spool
(7). Place the cover assembly (6) on the spool and press the cover assembly (6) with a hand.
Ma t
2. Install the cover (4) after aligning the holes. Tighten the socket bolts (1).
In
Bolt (socket): 98~114 N·m {10~11.6 kgf·m}
3. Install the dust ring (3) on the plunger. Install the cover (2) and fix the cover (2) with the cam-
shaft (5).
Contact surface between plunger and dust ring (5):

8.27 Hydraulic Cylinder AS - Disassemble and Assemble
Special tools
Application Tool Shape Necessity Quantity
Pulling out/pushing
■ 1
in the bushing
.
Press fitting the
De al
■ 1
dust ring
pt
g no
in ti
O-ring seal correc-

■ 1
tion
et a
Inserting tool Correcting tool

n
rk er
Inserting the cylin-

■ 1
der head
Ma t
In
Inserting the piston ■ 1

8.27.1 Disassembly
1. Drain the oil and remove the tubing.
2. Fix the cylinder.
● Fix the cylinder in a vertical or level

manner. A vertically fixed cylinder can
be disassembled and assembled eas-
ily.
● The pin bore in the head end can be

used for fixing of the cylinder. The pin
roll can prevent the cylinder from turn-
ing.
.
De al
● Remove the tubing in case of tubing in-
pt
terference while fixing the cylinder.
g n Fix the cylinder
o
in ti
et a
n
rk er
Ma t
ZX215-1006164
In
3. Removal of cylinder head

Approx 1.5m
● Unscrew the bolts with Allen Wrench.
● Using an extension rod, as shown in

the illustration on the right, will make
the work easy.
ZX215-1006165

4. Pulling out the piston rod
● Be sure to have removed the tubing

cover.
● Prepare a suitable container to collect

oil coming out of the oil port. 1 2
● After pulling out the piston rod to its

limit, slowly loosen the cylinder head
and pull it out. Sleeper
● Remove the piston rod (1) with the

cylinder head (2) and place them on a ZX215-1006166
wooden sleeper.
.
De al
pt
g n
5. Fixing the piston rod
o
● Use pin bore on the rod end or the flat
in ti
part of the ear to prevent turning of the Fixing 5

piston rod.
et a
n
rk er
ZX215-1006167
Ma t
In

6. Remove of the piston nut (5)

Drill bit
1) Remove the fixing screw (3) from the 3
piston nut (5).
NOTE: Around the fixing screw there

are two points that have been punched
against loosening. After removing the
riveted part with a hand drill, loosen
and remove the fixing screw (3).
2) Remove the steel ball (4). 4 ZX215-1006168
3) Remove the piston nut (5).
.
NOTE: The piston nut (5) is very tight.
De al
To loosen the piston nut (5), prepare 5
pt
a hydraulic jack or a spanner powered
by hydraulic cylinder. An extension rod
g n
should be ready when removing the
o
piston nut (5) manually.
in ti
Hydraulic jack
Hydraulic cylinder
et a
ZX215-1006169
n
rk er
7. Removal of piston assembly

Ma t
● Remove in turn the piston (7), buffer

In
sleeve (6) and cylinder head (2).

2 6 7
ZX215-1006170

8. Removal of the buffer sleeve (8) on the

bottom end Thread
1) Remove first the piston nut (5).

Piston rod
2) Use a tool like rubber hammer to tap
the piston nut (5) slightly for removal
while keeping the piston rod and the
buffer sleeve (8) intact. Remove the
elastic ring (9). 9 8 11
10
one gap (2 pcs)
3) Slide the buffer sleeve (8) toward the
ZX215-1006171
piston threads in order to remove the
two-piece stopper ring.
.
De al
4) Remove the buffer sleeve (8).
pt
5) There is an opening in the buffer seal
(10). Take advantage of this opening to
g n
remove the buffer seal (10).
o
in ti
9. Removal of piston seal

Screwdriver
1) The slide ring (12) and the guard
et a
ring (13) can be simply removed with 14 12

Piston
n
hands.
rk er
2) The seal (14) can be removed with a Bench clamp

hammer and a flat-head screwdriver.
3) Remove the O-ring seal (15) with a pry

Ma t
bar.
In
15 13
NOTE: The removed seals should not ZX215-1006172
be reused.
10. Removal of buffer ring (16)
NOTE: The buffer ring (16) is installed

18
in the inner groove in the cylinder head.
Use a tool with sharp end to pry it out and
remove it with a scraper.
20
17 16 19
ZX215-1006173

11. Removal of the U-ring (17) and the dust

ring (18)
Press
1) Remove the U-ring (17) with a tool such
as screwdriver.
Cushion
2) Pierce a tool (such as a screwdriver)
into the dust ring (18) and hammer the
screwdriver to remove the dust ring 21
(18).
NOTE: The removed seals should not

be reused. Support
ZX215-1006174
12. Removal of bushing (19)
.
De al
1) Remove the elastic ring (20) from the
pt
cylinder head (2) with a screwdriver.
g n
2) Push the bushing (19) out with the help
of clamps and press.
o
13. Removal of bushing (21)
in ti
1) Remove the dust ring (22) on the side

of cylinder barrel and piston rod with a
et a
tool such as screwdriver.

n
2) Remove the bushing (21) with the help

of a suitable cushion block.
rk er
Ma t
In

8.27.2 Assembly
1. Installation of bushing (21)
1) Use a mounting tool to press the bush- Press

ing (21) into the bushing (lubricated
with hydraulic oil) on the side of piston Mounting tool
rod and cylinder barrel. Cushion
21 Piston rod
2) Install the dust ring (22) with the help of 22
a suitable cushion block.
21
ZX215-1006175
.
De al
pt
2. Assembly of cylinder head (2)
Hydraulic press
g n
1) Use the press to push in the bushing
o
(19).
2
in ti
Tool
NOTE: Apply hydraulic oil to the inside
of cylinder head in advance. Make
sure that the bushing (19) pushed in is
et a
free from a raised shoulder.

19
n
2) Use the press to push in dust ring (18). Pressure surface

rk er
ZX215-1006176
Ma t
3) Install the guard ring and the U-ring (17)

In
sequentially in the U-groove.

18
NOTE: Tool
U-groove
● Install the U-ring (17) in correct direc-
tion. Make sure that the U-ring is intact
before installation. Press in
● Inverse installation will cause leak of

oil.
● Make sure that the U-ring is free from ZX215-1006177
any corrugation or permanent deforma-

tion after installation.

4) Installation of buffer ring (16)
NOTE: Make sure that the seal is in-

stalled in correct direction. Inverse in-
stallation can cause high pressure be-
tween the buffer ring (16) and the U-ring
(17), which may lead to deformation or
breakage of oil cylinder.
5) Install the elastic ring (20) to prevent

the fall of the bushing (19).
3. Assembling the piston assembly
1) Installation of seal (14).
.
De al
18
NOTE: Install first the O-ring seal and
pt
the one-side guard ring (13) on the pis-
ton. Place the piston on the press. As
g n
shown in the illustration on the right,
o
the seal (14) is installed with the tools
20
indicated. 17 16 19
in ti
ZX215-1006173
2) Correction of seal (14)
NOTE: Install the seal (14) and the

et a
guard ring (13) on the other side. In

n
order to prevent the expansion of the

seal (14), a corrector must be used to
rk er
Press
correct the seal (14) which has been Block Press
stretched during installation. The piston
Tool
rod may not be able to go in the cyl-
Ma t
13
inder barrel if the seal (14) is not cor-
In
rected timely. Tool Corrector

3) Installation of slide ring (12) Piston
NOTE: Slightly open the slide ring (12) 12 O-ring

and install it axially. Excessive opening 14
of the slide ring (12) can fail installation. 13
ZX215-1006179

4. Assembling the piston rod assembly
1) Fix the piston rod (1). Assembly tool 2
2) Install the cylinder (2) on the piston rod.
NOTE: Make sure that the dust ring lip

or the U-ring lip is not stopped by the
shoulder of any part. Install the cylinder
head and the piston rod with the tools.
1
3) If the bottom side of cylinder contains
ZX215-1006180
a buffer (not for bucket cylinder), install
the buffer bearing and the buffer seal in
the following order.
.
De al
pt
4) Let the notched side of the buffer seal
g n
(10) face the piston while installing the
buffer seal (10) in the groove.
o
in ti
5) Install the buffer sleeve (8) according to
the indication in the illustration on the Gap facing thread direction
right. Thread
et a
6) Install the stopper ring in the groove.

n
Install the elastic ring after the buffer Piston rod

sleeve (8) is pushed to the bottom. A
rk er
rubber hammer should be used for the

tapping job in order to avoid damaging
the piston rod and the buffer bearing.
Ma t
9 10 8 11
7) If the head side of cylinder contains a One gap (2 pcs)
In
buffer, install the buffer sleeve (6) and Head end buffer
ZX215-1006181
the buffer seal (23) according to the fol-
lowing order.
8) The piston nut must be installed after

installation of the buffer bearing.
9) The buffer seal (23) must be installed in

the groove, with its notches facing the
piston.

10) The buffer sleeve (6) must be installed

23 6
according to the illustration on the right. 5
11) Tighten the piston nut (5).
Piston nut (arm):
9600 N·m {979.6 kgf·m}
Piston nut (boom and bucket):
6200 N·m {632.6 kgf·m}

The notch side faces piston.
NOTE: Rod end buffer ZX215-1006182
● Insufficient tightening can cause oil
.
leakage, loose nut and thread break-
De al
age. In addition, excessive tightening
pt
can cause expansion of the buffer shaft
on the extending side or deformation of
g n
piston on the contact side.
o
● Thoroughly clean and grease (with ba-
in ti
nana oil) the threaded portions of the

piston, nuts and piston rod before tight-
ening the nuts.
et a
12) Treatment of the piston against loosen-

n
ing
rk er
NOTE: After the piston nut (5) is tight-

ened, put in the steel ball (4), tighten Punch
the setscrew (3) and punch to rivet the Rivet
Ma t
two peripheral points.

In
Setscrew (3):
66.9 N·m {6.8 kgf·m}

3
ZX215-1006183

5. Install the piston into the cylinder barrel Tool

Nylon sleeve
1) Fix the barrel in a vertical or level man- (2 pcs type)
ner.
2) Install the piston rod into the cylinder (Spread the

gaps by 180°)
barrel.
NOTE:
● If fixed in a vertical manner, the piston

rod falls into the barrel under its gravity.
● Make sure that the slide ring does not

fall while the piston is inserted into the
.
barrel.
De al
pt
ZX215-1006184
g no
in ti
6. Tightening of cylinder head

8 1
Tighten the cylinder head according to the
et a
sequence shown in the illustration on the 4 9

n
right.
12 5
rk er
Bolt: 267 N·m {27.2 kgf·m}

6 11
7. Install the tubing.
Ma t
10 3
In
2 7
Tightening sequence
ZX215-1006185

8.28 Work Equipment AS - Remove and Install
8.28.1 Removal
WARNING
● Fully extend the arm and the bucket.
Lower the work equipment to the
ground. Move the hydraulic lockout
control to the LOCK position.
● Release residual pressure in the hy-

draulic circuit.
.
De al
pt
See “Residual Pressure in Hydraulic Circuit -
Release” on page 6-40.
g n 5
1
o
1. Disconnect the grease hose (1).
3
2
in ti
2. Lift the boom cylinder assembly (2). Re-
move the lock bolt (3).
3. Remove the plate (4) and then the pin (5). 4

et a
NOTE: There are shims installed. Count

n
the shims and check the thickness. Place ZX215T-1006186

rk er
the shims in a safe place.

Ma t
4. Start the engine and retract the piston rod.

In
NOTE: Secure the piston rod with a wire

rope in order to prevent the piston from
slipping out. Put the cylinder on a bench or
support. Remove the grease fitting on the
bottom side in the later case. Remove the
other boom cylinder in the same way.
5. Remove the two hoses (6) of bucket cylin- 6 10 7

8 9
der and the those (7) of the arm cylinder.
NOTE: Cork the hoses to prevent outflow

ZXT225-1106028
of oil. Secure the hoses to the valve side.
6. Remove the inter-connector (8) used for

work lamp.

7. Lift the work equipment and remove the

plate (9). Remove the pin (10) from the
bottom.
NOTE: There are shims installed. Count 10

the shims and mark their locations.
9
ZX215T-1006188
.
8. Lift and disassemble the work equipment
De al
assembly. 11
pt
g n
Work equipment assembly: 3451 kg
o
in ti
et a
ZX215T-1006189
n
rk er
Ma t
In

8.28.2 Installation
CAUTION
● Do not put your finger in the pin bore
while aligning the pin bore.

NOTE: A clearance (a: 0.5~1.5 mm) shall

be left between the plate and the nut when
tightening the locknut.
.
De al
Greasing after assembling the pin:
pt
Grease (supramoly lithium base)
g n a
ZX215-1006190
o
in ti
NOTE: Adjust the shim thickness in order

to have a desired clearance (a: 0.5<a<1
et a
mm) between the piston end (12) and the

plate (4). 12 a
n
4
Standard shim thickness: 1.0 mm and 2.0
rk er
mm.
Greasing after assembling the pin:

Ma t
Grease (supramoly lithium base)

In
ZX215-1006191
Add hydraulic oil to the specified level.

Start the engine to circulate the oil in the
hydraulic system, and check the oil level
again. Add more hydraulic oil if necessary.
● Air bleeding
Bleed the air from travel motor.


8.29 Air Conditioner AS - Remove and Install
Special tools
ID Part Name Model Necessity Qty

Refrigerant Robinair
● 1
charger 34711-2K
S
Refrigerant Inoue Qing-
● 1
charger Hua
8.29.1 Removal
.
De al
CAUTION
pt
● Disconnect the cable from the negative
(-) post of the battery.
g n
1. Drain the coolant.
o
in ti
Coolant: approx. 22.5 L

2. Recover refrigerant from the air-condition-
ing system with the tool (S).
et a
n
rk er
S
Ma t
ZX215T-1006192
In
3. Remove the pad (1) on the cab floor.
ZX215T-1006193

4. Open the left rear cover of the cab with the

ignition key. Remove the outer filter ele-
ment (2).
Cover 2
W13092904
.
De al
pt
5. Remove the fuse box (3) and storage box
(4). g n
6. Remove outer covering (5).
o
7. Remove the air conditioner cover (6).
in ti
5
et a
n
4
3
rk er
6 ZX215T-1006196
Ma t
8. Remove the back air duct (7).

In
9. Remove the left air duct (8).
10. Remove the baffle (9).

10 7
11. Remove the right air duct (10). 8
ZXT225-1006205

12. Remove the cover (11).
13. Remove the cab's center connector (12).
14. Remove the radio antenna(13).
13
12
11
ZXT225-1006206
.
De al
pt
15. Remove the connector (14), connector (15)
and air conditioner wiring connection (16). 18
17
g n
Remove the two air conditioner relays (17),
three mounting bolts (18). Remove the
o
electrical mounting plate (19). 16
in ti
14
15
et a
n
19
rk er
ZXT215-1308207
Ma t
16. Remove the air conditioner water pipes (20)

In
and (21) as well as the dripping tube (22).
22 20 21
ZX215T-1006200

17. Remove the air conditioner unit (23).
NOTE: Also disconnect the two hoses con-

necting to the bottom of the air conditioner 23
when removing the air conditioner unit.
ZX215T-1006201
.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

8.29.2 Installation

NOTICE
● Keep the hoses free from contamination
by dirt, dust or water while installing the
return hose of the air conditioner.
● Make sure that the O-ring seal is pres-

ent in the connection before connecting
a hose of the air conditioner.
.
De al
● Make sure that the O-ring seals are free
pt
from any damage or deformation.
g no
NOTE: Apply compressor oil (ND8#) to the
threads of the parts connected with the re-
in ti
frigerant lines. Tighten the line connections

with a double-end spanner.
et a
Screw (hose clamp):

n
8.83~14.7 N·m {0.9~1.5 kgf·m}

rk er
Bolt (pressure plate):
13.5±1.2 N·m {1.38±0.12 kgf·m}

Ma t
● Refrigerant charging
In
Charge refrigerant (HFC-134a) into the air

condition return lines with tool (S).
For more information, see “Refrigerant” on

page 4-141.

8.30 Counterweight AS - Remove and Install
8.30.1 Removal
1. Remove the cover (1) from the counter-

weight. Install eyebolts to the counter- 1
weight. Hold the counterweight.
.
De al
pt
g n ZX225-1106004
o
2. Remove the four bolts (2).
in ti
Wire rope
et a
2
n
rk er
Ma t
ZX225-1106005
In
3. Lift the counterweight levelly with wire rope

or chain hoist.
NOTE: Be careful not to damage the

engine, radiator or cooler.
Counterweight assembly:
3901 kg
3
ZX225-1106006

8.30.2 Installation

Threads (mounting bolt - counter-

weight):
Thread adhesive (Tonsun 1277)
Mounting bolt (counterweight):
1,180~1,470 N·m {120~150 kgf·m}
Counterweight adjustment
.
De al
1. Move the counterweight with a crane to a
pt
suitable position on the frame.
2. Push the counterweight and install the

g n
bolts. Adjust the position of the counter-
Door
c=0±5mm
o
weight in such a manner that the following Counterweight
dimensions can be obtained.
in ti
● Clearance with swivel: a=10±4mm
10±5 mm(L&R)
et a
b=0±5mm
● Clearance with bodywork door:
n
Swivel
rk er
10±5 mm(L&R) ZX215-1006205
● Step from swivel in left to right direction

Ma t
b: max. 5 mm
In
● Step from bodywork door in left to right

direction
a: 10±4
● Step from bodywork top cover in upper

to lower direction
c: max. 5 mm

8.31 Cab AS - Remove and Install
8.31.1 Removal
CAUTION
● Disconnect first the cable connecting to
the negative (-) post of the battery.
1. Remove the floor mat (1).

1
.
De al
pt
g n ZX215T-1006193
o
in ti
(3).
3. Remove outer covering (4).

et a
4. Remove the air conditioner cover (5).

n
4
rk er
3
Ma t
2
5 ZX215T-1006001
In
5. Disconnect the left wire harness (6), moni-

tor harness connector (7) and window
washer harness (8).
7]’ 6
6. Remove the right side air duct (9).
ZXT225-1006216

7. Remove external air filter (10).
10
ZXT225-1006217
.
De al
pt
8. Disconnect the external air duct (11).
g no
in ti
11
et a
n
rk er
Ma t
ZX215T-1006210
In
9. Remove the storage box on the armrest

(12).
12
ZX215T-1006211

10. Remove the radio connector (13).
11. Remove the radio wire harness (14).
13
14
ZX215T-1006212
.
De al
pt
12. Remove the window washer reservoir (15).
g no
15
in ti
et a
n
rk er
ZX215T-1006213
Ma t
13. Remove the window washer pipe (16).

In
16
ZX215T-1006214

14. Remove the decor cover (17).
17
ZX215T-1006215
.
De al
pt
15. Remove the four mounting nuts (18) and
the five mounting bolts (19).
g no
in ti
19
18
et a
n
rk er
ZX215T-1006216
Ma t
In
16. Lift the cab assembly (20) for removal.
Cab assembly: 450 kg 20
ZX215T-1006217

8.31.2 Installation

Bolt: 200 N·m {20.4 kgf·m}
Nut: 210 N·m {21.4 kgf·m}
.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

8.32 Cab Window Glass – Disassemble and Assemble
10 10
9
8
1
10
.
7
De al
pt
g no
6
in ti
10 11
4
et a
5
n
12
rk er
10
3
Ma t
ZX215-1006218
In
(1) Right window glass (7) Left side rear window glass
(2) Front window glass (8) Rear window glass
(3) Lower front glass (9) Roof window glass
(4) Cab door window glass (upper) (10) Rubber sealing strip
(5) Cab door window glass (lower) (11) Center adjusting seal
(6) Cab door window glass (upper) (12) Front window AS (Glass and frame)
● Cab window glasses (1), (2), (5), (7) and (9) are adhered to the window frame.
● When replacing front window glass (2), disassemble front window assembly (12). (If the cab
is install with a front window assembly, do not only replace the front window glass.) For more
information about front window replacement, see “Front Window AS - Disassemble and As-
semble” on page 8-138.

8.32.1 Removal
CAUTION
● Removing shattered or cracked window
glass may cause finger cuts.
● Wear proper PPEs when removing shat-

tered cab window glasses.
NOTE: To avoid finger cut during when remov-

ing a shattered or cracked glass, cover it with
a piece of adhesive film or tapes.
.
De al
pt
1. Removal of glass (3)
g n
Glass (3) is hold in place by sealing strips.
Pull it upward carefully to remove it.
o
in ti
et a
n
3
rk er
ZX215-1006219
Ma t
In
2. Removal of glass (4) and (6)
1) Remove the sealing strip from the

frame of the cab door.
2) Push the glass outward carefully from

inside of the cab and remove glass (4)
and (6) together with the frame.
4
ZX215-1006220

3) Remove glass (4) and (6) from the

frame with a screw driver.
Frame
Seal
ZX215-1006221
.
De al
pt
3. Removal of glass (8)
g n
1) Remove the retainer from the groove
8
on the rubber with an ordinary screw
o
driver.
in ti
2) Put a thin bamboo chip inside part A of

the retaining rubber and detach the re-
tainer along the edge.
et a
3) Pat the glass from inside of the cab

n
and remove it. This job may require two

rk er
people. ZX215-1006222
Ma t
In
Rubber retainer side
Rubber retainer Glass
Cab side Retainer
A A
Cab
ZX225-1006231

4. Removal of glass (1), (2), (5), (7) and (9). 9
ZX215-1006223
.
De al
pt
1) Remove the resin board, decor strip
and retainer along the edge of the
g n Cab
glass. Glass
o
Drill
2) Punch a hole through the adhesive with
a drill (or a cutter) as illustrated.
in ti
et a
n
Adhesive
rk er
ZX215-1006224
Ma t
3) Pull a piece of piano string (or steel

In
wire) through the hole as illustrated.
Piano string
(or steel wire)
ZX215-1006225

4) Fix both ends of the piano string onto

two screw drivers. Pull the wire back Cab (Outside)
and forth in order to cut the adhesive
and detach the glass from the cab. This Glass
job may require 2-3 people.
● Run the string along the center of the

adhesive. The string may break when
it becomes very hot. Use different sec-
tions of the string while cutting the ad-
Adhesive
hesive.
(Inside)
ZX215-1006226
.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

8.32.2 Installation
● Reverse the disassembling sequence

when installing glasses (3), (4), (6) and
(8). Follow the procedures below to install
glasses (1), (2), (5), (7) and (9).
1. Clean the remaining adhesive and rubber

on cab frame (contact surface) with a knife
or scraper [5].
● Remove the remaining adhesive and

rubber so that they will not affect the 5
application of new adhesive. Do not
.
scrape the original paint on the surface.
De al
ZX215T-1006227
(Scraping of paint reduces the perfor-
pt
mance of the adhesive.)
g no
2. Clean the grease, dust and dirt on the cab
(8) and the glass (9) with unleaded gaso-
in ti
line.
● Contaminant on the contact surface re-

et a
duces the performance of adhesive.

n
● Clean the black part on the back of the 8

rk er
glass.
● After cleaning, dry the glass for at least

5 minutes.
Ma t
ZX215T-1006228
In
ZX215T-1006229

3. Priming coat (10)
● Priming paint expires 4 months after

production. Do not use expired paint.
● Use the paint within 2 hours after it is

Cab
unsealed. 11
● Use the paint within 24 hours even if it

10
is sealed again immediately after un-
Old adhesive edge
sealing. (Dispose the paint 24 hours on cab side
after it is unsealed)
1) Make sure the adhesive paint and glass

priming paint are well agitated before ZX215-1006230
.
De al
application.
pt
● If the priming paint is stored in a refrig-
erator, keep it under ambient tempera-
g n
ture for at least half a day before agita-
o
tion.
in ti
● (If the paint is unsealed immediately af-

ter it is taken out of a refrigerator, water
will condense on it.)
et a
2) Always wash a used brush (11) with

n
unleaded gasoline before using it.

rk er
● Check the brush for contaminants after

it has been washed.
● Prepare two brushes for priming paint,

Ma t
one for painted surface and the other

In
for glass surface.

3) Apply priming paint (for painted sur-

face) evenly onto the surface where
sealing rubber is to be adhered and
where adhesive agent is to be applied 8
(on the cab (8)).
Priming paint (for painted sur-

face): Sunrise MSI Primer 24
● Do not apply primer more than twice;

otherwise, the performance of the prim-
er will be reduced.
ZX215T-1006231
.
De al
pt
● Applying location: Cover the whole area
of (a). Dimension of (a): 25mm
g n
8
o
in ti
6
et a
a
n
rk er
ZX215-1006232
● Besides the above locations, apply

Ma t
primer also onto the right window glass

and the cab door lower window glass.
In
● Additional priming area on the right

b
window glass: (b)
● Additional priming area on the cab

door lower window glass: (c)
ZX215-1006233

● Dry the primer for at least 5 minutes

(within 8 hours).
● Do not use wrong priming paint.
If, for example, glass primer is mistak-

enly used, wash it with unleaded gaso-
line.
c
ZX215-1006234
.
De al
4) Apply priming paint (for glass surface)
pt
onto the contact surface of window
9
glass (9).
g n
Glass primer:
o
Sunrise MSI Primer 35
in ti
● Do not apply the primer more than

twice; otherwise, the performance of
et a
the primer will be reduced.

n
rk er
ZX215-1006235
● Priming area: Apply the priming paint

Ma t
on the contact surface of glass (9) 8

In
(rubber seal (6)adhering location) and

along cab frame (8).
6
● Leave a 5 mm margin uncoated along
the black strip adjacent to the clear d
area of the glass.
● When priming paint has been coated, 9

dry it for at least 5 minutes (within 8
hours). ZX215-1006236
● Do not use wrong primer.
If wrong glass primer is used, wash it

with unleaded gasoline.

4. Adhere rubber seal (6) (with adhesive tape

on both sides) along the inner edge of the
contact surface of the glass. 6
● Do not detach the waxed paper on the

rubber seal before the window glass is
installed.
● Do not touch the cleaned area on the

glass before rubber seal is adhered.
● Be careful not to allow the rubber seal ZX215-1006237

on the corners to peel off.
.
De al
pt
● When sticking rubber seal (6) along the
e
g n
window frame, do not overlap the two
ends of the seal. A 5 mm gap between
o
6
the two ends of the seal is recommend-
in ti
ed.
1) Stick rubber seal (6) onto the right cab

window frame as illustrated.
et a
n
rk er
ZX215-1006238
Ma t
● Adhere additional rubber seal (6a) onto

In
f
the right cab window 6a
Position of the additional rubber seal:
(f): 50 mm
h
(g): 90 mm
(h): 250 mm
ZX215-1006239

2) Adhere rubber seal (6) on the left cab

window as illustrated.
ZX215-1006240
.
De al
3) Adhere rubber seal (6) onto the lower
pt
cab door window as illustrated.
6
g no
in ti
et a
n
ZX215-1006241
rk er
● Adhere additional rubber seal (6b) onto

Ma t
the lower cab door window frame as il-

lustrated. j
In
Position of additional rubber seal: 6b
(j): 110 mm
m
(k): 90 mm
(m): 200 mm
k
ZX215-1006242

4) Adhere rubber seal (6) onto the front

window glass as illustrated.
6
ZX215-1006243
.
De al
● Different from the rubber seal (6) on
pt
other window, rubber seal (6c) on the
bottom of the front window shall be
g n
adhered onto the external edge of the
o
lower part of the front window frame. 6
6c
(If it is adhered along the inner edge,
in ti
the rubber seal will be seen through the

clear part of the glass.)
et a
n
rk er
ZX215-1006244
5. Positioning of new window glass
1) Check the clearance between the edge

Ma t
of glass and the cab in 4 directions, 9

In
and position the glass. Make sure the

clearance is even. n
2) Put a tape [6] across the glass (9) and
cab (8) and draw a line (n) on it for [6]
alignment.
● Adhere tape [6] at 3 points as illustrated

for precise alignment of right window
glass, left rear window glass and cab 8
door lower window glass. ZX215T-1006245
3) Cut the tapes across the glass (9) and

the cab (8) and remove the glass.
● Do not remove the tape on the left side

of the glass until the glass is installed.

● When positioning front window glass,

cover it across the width of the window
frame in the horizontal direction.
[6]
[6]
Set the clearance (p) between the top
edge of the glass and the upper frame
at 3 mm when positioning it in the verti- 8 [6]
cal direction.
ZX215-1006246
.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

6. Adhesive
● Store adhesion agent in dark places

where temperature is blow 25°C.
13
● Do not heat the adhesive to above
30°C.
● Before using adhesive that has been

unsealed, remove the hardened part at 12
the nozzle.
1) Open the aluminum seal (13) on the

head of the cylinder (12) and install the
nozzle (14). ZX215-1006247
.
De al
Adhesive:
pt
Sunrise MSI SR sealant U90 4463876
g no
2) Cut the tip of nozzle (14) as illustrated.
in ti
Dimension of the cut:

14
(q): 10 mm r
et a
(r): 5 mm
n
q
rk er
Ma t
ZX215-1006248
In
3) Set the cylinder (12) in the gun [7].
● An electrical caulking gun is more ef- 12 [7]

ficient.
ZX215-1006249

4) Remove the waxed paper of the rubber

seal on the surface where adhesive is
to be applied. 15
6
5) Apply adhesive (15) along the external
edge of the rubber seal (6).
ZX215-1006250
.
De al
● Adhesive (15) for rubber seal (6) on
pt
cab (8) shall be applied as illustrated:
8
Dimension of (s): 10 mm
g n s
Dimension of (t): 15 mm
o
● Adhesive (15) shall be thicker that the 6
in ti
rubber seal (6). t

15
● Apply adhesive of the same thickness
et a
evenly.
n
ZX215-1006251
rk er
Ma t
In

● Apply adhesive (15) onto the additional

rubber seal of the right window (6a) and
6a
additional rubber seal of the cab door 15
lower window (6b).
ZX215-1006252
.
De al
pt
6b
g no
15
in ti
et a
n
rk er
ZX215-1006253
7. Install window glass

Ma t
1) Install window glass (9) and align it with

In
the mark on the cab. (See step 5)
● Since the glass can not be remove

once installed, be very careful when
performing this task. 9
● Install the glass properly within 5 min-
utes after adhesive has been applied.
2) Press the perimeter of the glass (9)

ZX215T-1006254
after is has been put in place until it is
securely stuck to the rubber seal.
● Press the corners of the glass hard.

● After the front window glass has been

installed, fill the clearance between the
glass on area (s) and the center adjust-
ing seal (16) to the dimension of (t) and
(u). Coat primer onto glass (4) on sec-
A
tion A-A and apply the adhesive as fill-
ers.
A
Dimension of (t): 2 mm S
Dimension of (u): 5 mm
● Use a rubber spatula to cover the edge

of the glass and trim the adhesive. t
4
.
De al
● Remove surplus adhesive.
pt
Glass primer:
g n Sunrise MSI Primer 35 u
o
Adhesive:
16
in ti
Sunrise MSI SR Sealant U90 4463876 A-A

ZX215-1006255
et a
n
8. Fix the glass

rk er
1) After the right window glass (1) has

been adhered to the cab, put position-
Ma t
ing chips a (1 or 2 pcs) beneath the

glass in order to fix it.
In
a
ZX215T-1006256

2) Use foam polystyrene blocks [9] and

rubber band [10] to fix the glass and [10]
the rubber seal as illustrated.
9. After the glass has been fixed, remove all

the remaining primer and adhesive on the
cab and on the glass.
● Clean the adhesive with unleaded gas-

oline before it is hardened.
[9]
● Do not apply impacting force onto the
glass when cleaning it. ZX215-1006257
10. Protection of fixed window glass
.
De al
1) Remove the positioning chips, foam
pt
polystyrene blocks and the rubber band
after 10 hours.
g n
(Condition: Temperature: 20; humidity:
o
60%)
in ti
2) Wait for another 14 hours after the re-

moval of positioning chips, foam poly-
styrene blocks and rubber band before
et a
operating the machine.

n
rk er
Ma t
In

8.33 Front Window AS - Disassemble and Assemble
NOTICE
● Before removing the front window as-
sembly, lower the work equipment onto
the ground and shut down the engine.
The front window assembly must be removed

from the cab in order to replace the front win-
dow glass.
8.33.1 Disassemble
.
De al
pt
1. Raise the front window assembly to the
roof and secure it with the rear locks (at
g n
both sides).
o
2. Remove left corner plate (1) and right cor-
ner plate (2).
in ti
● Mounting bolt (4) and washer (3) of the 2

left corner plate will be used in Step 6
4
et a
to hang the pull rod. 3

1
n
ZX215-1006258
rk er
Ma t
3. Release the rear lock of the cab.

In
4. Lower the front window assembly carefully

a bit. Take out and hold the rollers (5) and
(6) at the bottom of the front window from
the removed parts in Step 2.
5. Remove roller (5) and (6) from both sides

of the bottom of the front window.
6 5
ZX215-1006259

6. Remove pin (7) at the lower left side.

9
● Plate (8) at the end of the pull rod (9)
will come out by removing of pin (7).
8
● Hang plate (8) onto the mounting bolt
of left corner plate (using the washer)
and fix it. 6
NOTICE
7 ZX215-1006260
● A return load of 58.8 N {6 kg} is applied
onto the rear of the cab. Be very care-
.
ful when removing pin (7) to disconnect
De al
pull rod (9).
pt
g no
9 8
in ti
et a
n
rk er
ZX215-1006261
Ma t
7. Pull out the front window assembly (10)

In
from the opened part of the guide rail and 10

lower the assembly gradually.
ZX215-1006262

8. Lower the front window assembly (10)

completely.
10
● Be careful not to allow the front window
assembly to damage the machine mon-
itor.
ZX215-1006263
.
De al
pt
9. Move the front window assembly (10) to 12 11
the right and the left and remove the two
g n
upper rollers (11) and (12) from the guide
rail. Then, remove the front window as-
o
sembly (10).
in ti
et a
n
rk er
10 ZX215-1006265
Ma t
In

8.33.2 Assemble
● Reverse the disassembling sequence.
● Adjust the opening and closing of the front

window assembly as per the following in-
struction.
1. Open and close the front window assembly

and check if it interferes with the guide rail.
Check if the roller is jammed.
2. If the front window can not be opened or

closed properly, loosen the mounting bolt
of the roller adjusting bracket (13) and
.
De al
adjust the condition of the front window.
pt
Tighten the mounting bolt after adjusting.
Mounting bolt:
g n
13
o
34.3 N·m {3.5 kgf·m} ZX215-1006266
in ti
3. Raise the front window assemble and fix it

et a
with rear locks (at both sides).

n
● Check if the locks at the rear of the cab

are securely fixed.
rk er
a
4. Install the right corner plate (2).
Ma t
● After the "locked" position is adjusted in

2
Step 6, tighten the corner plate.
In
a
● Install the right corner plate. Clearance ZX215-1006267
(a) between the guide rail and the right
corner plate (2) is 0 – 2.0 mm.
● Install the right corner plate. Keep the

surface (R) of the roller without a level R
error.
ZX215-1006268

5. Install left corner plate (1)
● After the "locked" position is adjusted in

Step 6, tighten the corner plate. b
● Install left corner plate. Clearance (b)

between the guide rail and the left cor-
ner plate (1) is 0 – 2.0 mm.
b
● Install left corner plate and keep the
surface (R) of the roller without a level
1
error. (See previous illustration).
ZX215-1006269
.
De al
6. Adjust the "locked" position of the lock of
pt
front window assembly as per the following
instruction.
g n
1) Tighten the left corner plate (1) and the
o
right corner plate (2) in a nearly correct
in ti
position so that front window glass (14) 15

is pressed closely against the adjusting
seal (15) on the cab.
et a
14
n
rk er
ZX215-1006270
2) Open and close the front window as-
sembly and check the working condi-
tion of left lock (16) and right lock (17).
Ma t
● If left lock (16) and right lock (17) do

In
not work properly, Loosen the mounting

bolt (19) of the lock and move the lock
(16) forward. Tighten the bolt after that.
16 17
● Adjust the right lock with the same
method.
3) Check again the adaptability between

the front window assembly (14) and
the adjusting seal (15) on the cab.
(Checked in Step 1) ZX215-1006271
● Tighten the mounting bolts of the left

and right corner plates when the left
and right locks (16, 17) are properly in
place.

7. After adjustment is finished, flush the front

window glass and check if any water leaks
into the cab.
16 18
ZX215-1006272
8. Adjust the "locked" position of the lock of
.
De al
front window assembly
pt
1) After the "locked" position of the lock of
g n
front window assembly is adjusted in
Step 6 and Step 7, raise the assembly
o
to the roof.
in ti
2) Set the locks of the front window as-

sembly at the rear of the cab at the
19 18
"locked" position, and check the follow-
et a
ing items:
n
● Check the conditions of left lock (16)

rk er
ZX215-1006273
and right lock (17).
● The front window assembly must con-

tact the left and right rubber stopper
Ma t
(18), and the rubber stoppers must be

In
pushed backward by 1.5 – 3.0 mm.
● The front window assembly shall push 18 20

the limit switch 4 – 7mm backward.
ZX215-1006274

3) Close the front window assembly (10).
4) Loosen the retaining nut (20) at the left

and right side of rubber stopper (18),
and pull the two rubber stoppers (18)
inward so that they can not contact the 23
"unlocked" front window assembly. 21 22
5) Adjust the position of latch bolt (21).
● Latch bolt(21): M10, Inner diameter of ZX215-1006275

plate (23): ø14.5 mm
.
De al
pt
6) Adjustment of left and right rubber stop-
per (18)
g n
● Allow front window assembly (10) to
o
contact the left and right rubber stopper
in ti
(18). (when the lock is "unlocked")
7) Lock front window assembly (10).

10 18
et a
n
ZX215-1006277
rk er
Ma t
8) Turn the left/right rubber stopper (18) to

In
the left by one and a half round.
● Turning the rubber stopper (18) leftward

for one round is equivalent to pressing
it by 1.5 mm.
● When front window assembly is "un-

locked", it must move the left/right rub-
18
ber stopper (18) by 1.5 – 3.0 mm.
9) Tighten the retaining nuts (20) at both ZX215-1006278

sides of the rubber stopper (18).

9. Adjust the front window assembly retainer

(24).
● Adjust and lock both sides of the retain-

er (24) so that surface (d) of stopper
(D) of front window assembly contacts
24
surface (c) of retainer (24) when front 10
window assembly is raised.
D
ZX215-1006279
.
De al
pt
10. Check the locking ability of front window
assembly.
g n
● After the adjustment from Step 6 to
o
Step 9 is finished, check the locking 24
in ti
force of left lock (16) and right lock (17). D
● Check the locking force at the "locked" d

side (front of cab) and the "unlocked"
et a
side (rear of cab).

n
c
Left lower pin:
rk er
ZX215-1006280
27 – 34 N·m {2.75 – 3.47 kgf·m}
Mounting bolt:
Ma t
Adhesive(LT-2)
In
16 17
ZX215-1006271

8.34 Monitor - Remove and Install
8.34.1 Removal
CAUTION
1. Unscrew the three bolts (4). Remove the

mounting plate and the monitor assembly
from the bracket (3). 3 4
.
De al
5
2. Remove the nut (1) and the gasket (2) to
2
pt
separate the monitor (5) from the mounting
plate. g n 1
o
in ti
ZX215-1006281
8.34.2 Installation
et a

n

rk er
Ma t
In

8.35 Controller AS - Remove and Install
8.35.1 Removal
CAUTION

(2).
2. Remove rear covering (3).
.
De al
3. Remove air conditioner cover (4).
pt
g n 3
o
in ti
1 4
2
ZXT225-1006292
et a
n
4. Remove the controller wiring connectors

rk er
A1(5) and A2(6).
5. Remove the four bolts. Remove the con-

Ma t
troller assembly (7).

In
6 5
ZX215-1308283
8.35.2 Installation


8-148
2. Wiring
8.36 Radio
1. Main structure
RED — L. SOUND TRACK INPUT 8.36.1 Structure
In
AUDIO INPUT
WHITE — R. SOUND TRACK INPUT

Ma t
Disassembly and Assembly
RED — ACC IGNITION

rk er
YELLOW — BATT POWER SUPPLY
n
BLACK — GROUND
et a
GRAY — R. SOUND TRACK OUTPUT +
POWER, GROUND AND AUDIO OUTPUT

BACK PANEL
— R. SOUND TRACK OUTPUT –
in ti
WHITE — L. SOUND TRACK OUTPUT +
o
Shop Manual - November 2014

BLACK — L. SOUND TRACK OUTPUT –
g n
RADIO ANTENNA
De al
pt
.
ZX215-1006285
ZX215-1006284
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.36.2 Removal
NOTICE
● Disconnect the power supply prior to
removal.
1. Remove the console cover.
Arm rest cover
.
De al
pt
g no
Radio
ZX215-1006286
in ti
2. Remove the radio connector CN-003F.

et a
n
rk er
Ma t
In
Connector CN-003F Cab harness

ZX215-1006287
3. Remove the four screws and the washers

in order to remove the radio and the radio
mounting brackets from the console cover.
Arm rest
4. Remove the four screws and the washers
in order to remove the radio from the radio
mounting brackets.
Radio
Mounting bracket Washer
Screw
ZX215-1006288

8.36.3 Installation

8.36.4 Connector model and wiring
1 2 3
.
20b R+ L+
De al
1 2 3
pt
0 28 R- L-
4
g n5 6 7
4 5 6 7
o
Harness socket terminals
in ti
Raido wiring terminals

Type: Yasaki 7119-3070
ZX215-1006289
et a
n
rk er
Ma t
In

8.37 Battery
8.37.1 Structure
A
2 B
10 J
C
11
.
6 E
De al
D
pt
g n
I
o
in ti
H
et a
n
F
8 7 5 9 4 3 1
rk er
ZX215-1006290
Ma t
(1) Spinning post (7) Paste (active material)

In
(2) Charge densiometer (8) "Bag-type" screen

(3) Heat-sealing cover (9) Polar group
(4) PP casing (10) Liquid-gas separator
(5) Central polar ear (11) Central busbar
(6) Forged grid

8.37.2 Removal
NOTICE
● Turn the start switch to the OFF posi-
tion before removal.
● Do not remove the charge densimeter.

Tighten the densimeter clockwise, if it Bolt Terminal Grounding cable
is loosened, with a suitable tool.
1. Removal of battery grounding wire VART

A
● Open the tarpaulin, unscrew the bolt, and
.
De al
remove the terminal from the battery wiring
pt
post. Battery
‫ ܡ‬㓈 ᡸ
㪘 ⬉ ∴
$77(5<
)5((%
1$1*(
0$,17(
g n
CAUTION
o
ZX215-1006291
● Battery gas can cause explosion. No

sparks or flames are allowed near the
in ti
battery.
Battery cable
2. Disconnect the battery wiring cable and the
et a
battery breaker cable.

n
VARTA
rk er
VARTA
Ma t
Battery Breaker cable

In
ZX215-1006292
3. Remove the four bolts and washers. Re- Battery

move the battery assembly from the bot-
tom plate. Remove the battery.
VAR
TA
TA
VAR
Bolt Wahser Battery box
ZX215-1006293

8.37.3 Installation

8.37.4 Replacement
There are two 12V batteries with ground-

ing negative (-) posts in the machine. If one
battery fails in the 24V system, it must be re-
placed with one of the same type. Batteries of
different types are probably charged at differ-
ent speeds, which may cause one of them to
.
De al
fail due to overloading.
pt
g n
NOTICE
o
● During installation, apply vaseline to
in ti
battery terminals in order to prevent
corrosion.
et a
n
rk er
Ma t
In

8.38 Start Switch
8.38.1 Structure
23 22 20 18 17 15 13 12,11 28 6 10,9,8,7
.
De al
pt
g no
in ti
et a
25,24 21 1 14 19 16 26 5 4,3,2
n
rk er
27
Ma t
In
4 5 6
1 2 3
ZX215-1006294
(1) Housing (8) Shield (15) Cover (22) Contact SPR-A

(2) Key (9) Pin (16) Spring (23) Contact B
(3) Ring (10) Spring (17) Ball (24) Terminal
(4) Knob (11) Disc (18) Spring (25) Bolt
(5) Nut (12) Spring (19) Contact SPR-B (26) O-ring seal
(6) Cylinder (13) Plug (20) Contact A (27) Harness AS
(7) Cap (14) Rotor (21) Seat (28) Washer

8.38.2 Removal
NOTICE
● Disconnect the power supply of the
start switch before removal.
;
7 0$
67$5
1. Remove the setscrew to remove the con-

21
2))
sole cover.
&.
/2
0,1
.
Start swich Console cover Set screw
De al
pt
ZX215-1006295
g n
2. Remove both setscrews in order to remove Set screw Console cover
the mounting plate and the start switch
o
from the console cover.
in ti
et a
n
rk er
Mounting plate Start switch

ZX215-1006296
Ma t
In
3. Remove the nut so as to remove the start

switch from its mounting plate.
Start switch Mounting plate Nut

ZX215-1006297

Working principle and wiring of start switch
1. Working principle
ON/OFF
Key Position Preheat Plug
Battery (B) Battery Relay (BR) Accessory Start Relay (C)
(R1) (R2)
HEAT
OFF
ON
START
.
De al
2. Wiring
pt
g no
in ti
1 B BR ACC 3 1 22 13 3
et a
4 R1 R2 C 6 4 16 11 6
n
HARNESS PLUG TERMINALS

rk er
JACKET MODEL˖YAZAKI 7123-7464-30

KEY SWITCH WIRING TERMINALS
JACKET MODEL˖YAZAKI 7222-7464-30
Ma t
ZX215-1006299
In

8.39 Fuse Box
8.39.1 Removal
1. Remove the cover. Cover
ZX215-1006300
.
De al
pt
2. Remove the bolts and take off the back
cover along with the fuse box. Back cover Fuse box cover
g no
in ti
et a
n
Bolt
rk er
ZX215-1006301
Ma t
3. Remove the bolts so as to separate the

In
Fuse box harness

fuse box and harness assembly from the
back cover. Bolt
Back cover
ZX215-1006302

8.40 Wiper
8.40.1 Structure
Blade
Rotating mechanism
Arm
.
De al
pt
g n Wiper motor
Connector
o
in ti
Mounting bracket
et a
ZX215-1006303
n
8.40.2 Working principle

rk er
Ma t
In
GREEN (LOW SPEED)
YELLOW (RESET)
M
BLUE (HIGH SPEED)
RED (POWER+)
BLACK (POWER-)
ZX215-1006304

8.40.3 Removal
1. Remove the decorative button in order to

remove the interior decoration.
Decoration
button
Inner decor
.
De al
ZX215-1006305
pt
g n
2. Remove the moving mechanism and the
o
motor.
Bolt
in ti
● Unscrew the bolts to remove the wiper

motor and moving mechanism from the Moving
cab. mechanism
et a
Wiper motor
n
rk er
Bolt
ZX215-1006306
Ma t
In
3. Remove the arm and the blade.
● Unscrew the nut to remove the wiper

arm and blade from the cab.
Arm bracket
Cap
Locknut
Cab
ZX215-1006307

8.40.5 Installation

8.40.4 Angle adjustment of wiper arm
● The arm should stops moving when the Stopper

blade reaches the stopper.
● If the arm is still working when the blade

reaches the stopper or the arm already Blade
stops working before the blade reaches the
.
De al
stopper, the moving angle of wiper should
pt
be adjusted to prevent breakdown of the
wiper. g n Arm
● Adjust the wiper in such a way. Loosen the

o
locknut; adjust the arm working angle ac-
cording to actual condition. Make sure that
in ti
the wiper motor stops working at the mo-

ment that the blade reaches the mechani- Locknut
cal stopper.
et a
n
rk er
ZX215-1006308
Ma t
In

8.41 Relay
8.41.1 Engine relays
1. Starter relay - check S
● Check the conduction and action. Replace

the relay in case of any failure.
S
B 1 SW(-) SW L
AA2A
.
2 L(-)
De al
ZX215-1006309
pt
g n
2. Mains relay - check
o
1(+)
● Check the conduction and action. Replace 2(-)
in ti
3 4
et a
Battery (+) terminal

3 4
n
rk er
1(+)
2(-)
ZX215-1006310
Ma t
In
3. Heater relay
5(-)
1
5 1 2 3 4
(-) (+)
2 4(+)
Fuse 3
ZX215-1006311

4. Safety relay
Measure the resistance between terminal

2 and terminal 3.
Standard Value Approx. 200Ω

(P)6
3(R)
5
2(L)
(E)4
8.41.2 Other relays 1(S)
ZX215-1006312
1. Function and location
.
De al
pt
Shutdown delay relay
g no
Starter control relay Work lamp relay Relay harness
Head lamp relay

in ti
et a
n
rk er
Ma t
In
Parking relay Pilot control relay

Horn relay
Mounting plate
ZX215-1006313

2. Removal
1) Remove relay from its seat.

Relay harness Mounting plate
2) Remove the screw in order to remove the
relay seat and harness from the mounting
plate.
3. Installation

Relay seat Screw Relay
.
De al
ZX215-1006314
pt
g no
in ti
et a
n
rk er
Ma t
In

4. Relay connector and wiring
1 4 2
Relay wiring terminals
Relay model: HELLA 4RD 007 903-027
.
De al
pt
g no
Horn relay Work lamp relay Pilot control relay Starter control relay Parking relay Head lamp relay Shutdown delay relay
K5 K6 K10 K3 K7 K8 K9
in ti
32 34 27 11 64 70 21
31 0 33 0 105 0 0 13
105 0 13 0 72 0
606
65
12
et a
23 24 63 71 15
n
rk er
Harness socket terminals
Socket model: Jacket 8JA003526-00

ZX215-1006315
Ma t
In

8.42 Sensor
1. Water temperature sensor - check
● Put the sensor into a vessel containing en-

gine oil.
1
● Heat the oil to the specified temperature.
Stir the oil at the same time.
Sensor body
● Measure the resistance value between the
terminal 1 and the sensor body at different
temperatures.
.
50±0.2°C 80±10Ω
De al
60°C 56.3Ω(ref.)
pt
ZX215-1006316
Standard 80°C
g n 29.5Ω(ref.)
Value 100°C 16.5Ω(ref.)
106±0.3°C 14.3±1.0Ω
o
120°C 10Ω(ref.)
in ti
● Replace the sensor if the measured value

exceeds the standard one.
et a
n
rk er
2. Engine speed sensor - check
● Measure the resistance between terminal

1 and terminal 2.
Ma t
Std. Value(25°C) 2.3±0.2kΩ

In
● Replace the sensor if the measured value

exceeds the standard one.
2 1
ZX215-1006317
NOTICE
● Insufficient tightening of the engine
speed sensor may cause signal output
failure. Tighten the sensor to specified
torque.

3. Pressure sensor - check
● Input volt: 4.75~5.25VDC
● Output volt: 0.5~4.5V
● Pressure range: 0~50BAR
4. Fuel level sensor - check
● Swing the float up and down in order
.
to measure the effective angle of radial
De al
swing, i.e. the line through the float and the
pt
Float
turning point will swing 105°.
g n
● Swing the float up and down. The vertical
o
distance between the upper limit and the
Lever
lower limit of the float should be 500 mm.
in ti
● Move the float to its upper limit. Measure

the resistance between the sensor terminal
et a
R and ground with a multimeter. The mea-

Ternimal R
sured resistance should be Ru ≦ 9.6Ω. Casing
n
● Move the float to its lower limit. Measure

rk er
the resistance between the sensor terminal Connector
R and ground with a multimeter. The mea-

ZX215-1006319
sured resistance should be Rd ≧ 86Ω.
Ma t
In

8.43 Connector Terminals - Insert and Remove
8.43.1 Insertion
1. Hold tightly a wire terminal at a distance of

about 25 mm from its end.
.
De al
ZX215-1006320
pt
g n
2. Hold the connector. Let the rear seal face
o
you.
in ti
et a
n
rk er
ZX215-1006321
Ma t
In
3. Align the terminal with a hole on the seal

and push it perpendicularly to the bottom.
Slightly pull back the wire in order to en-
sure that the terminal is locked in place.
ZX215-1006322

8.43.2 Removal
1. Hold the connector, with its back end fac-

ing you. Select a suitable tool and clip on
the wire.
ZX215-1006323
.
De al
pt
2. Push the tool along the wire into the con-
g n
nector so that the tool can expand the ter-
minal lock shoulder and reach its flanged
o
part.
in ti
et a
n
rk er
ZX215-1006324
Ma t
3. Pull out the tool to remove the wire with

In
terminal.
ZX215-1006325

tE.
PAD nal
eGp
ng o
i
tKi t
a
AkNe rn
ar e
BLM Int

tE.
l
Pg Aona
DG
ep
in ti
etK a
n
ArkNer
Ma t
BL In

SY195/205/215/225C9 Crawler Hydraulic Excavator System Schematics
System Schematics
.
9 System Schematics
De al
pt
9.1 Hydraulic System Diagram ...................................................................................... 9-3
9.2 Air-Conditioning Electrical Circuit Diagram .............................................................. 9-4
g n
9.3 Fuse Box Relay ....................................................................................................... 9-5
o
9.4 Control Switches and Monitor Electrical Diagram ................................................... 9-6
in ti
9.5 Operator Cab Electrical Circuit Diagram.................................................................. 9-7

9.6 Chassis Electrical Circuit Diagram........................................................................... 9-8
et a
n
rk er
Ma t
In

System Schematics SY195/205/215/225C9 Crawler Hydraulic Excavator
.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In
WARNING
jury or death.

9.1 Hydraulic System Diagram

P2
A8
A7 PPC LOCK VALVE

TO PnA2
A6 BOOM TO ARM PRIORITY
.
TO MAIN VALVE Xbp2
A5 BKT CONFLUENCE
TO MAIN VALVE PsP
pt
SWING MECHANISM
A4 SWING PRIORITY
TRANSITION BLOCK ARM

A3
TO MAIN VALVE PbL (P5) (P4)
TO SWIVEL JOINT SIGNAL PORT BOOM DOWN TO MAIN VALVE XBb1
A2 TRAVEL SPEED
De
A1
XBp2
P1 T SH R2
BKT DUMP TO MAIN VALVE XBk
PaL
BYPASS CUT
(XBp1)
HVa
CCO
PG (ROD) Aa
᥹(ROD) Aa
TO MAIN VALVE XAb1 CCk
T P BOOM UP TO MAIN VALVE XAb2

P4
BaR
AaR Ba
g
(HEAD)
ARM2 XAa2
XBa2
XBa1
XAa1 ARM1
BUCKET
LCa
BUCKET Dr7 LCAT2 LCAP2 4ĳ1.0

Dr3
n
BKT DIG TO MAIN VALVE XAk A6 PnA2
P3 (HEAD) Ak AkR
BoR AR
(Bo)
M (ROD) Bk
P2 BOOM BkR AoR (Ao)
R TRAVEL BUCKET XAk
ti
XAb2
XBk
PCK
(XAo) OPTION
(XBo)
BOOM L TRAVEL LCK
LCo
PbL
P1 HVb
(HEAD)
Ab CCb
TO MAIN VALVE XBa1
e
ARM IN
TO MAIN VALVE XBa2 AbR BbR
(XAb2)
Pck BOOM2
T P P2
(ROD)
Bb
A B XAb1
TO MAIN VALVE XAs BOOM1
rk
L SWING XBb1
PsP
A4 PRIORITY
ARM
Dr1 C2
LCb
Pns
SWING
᥹As
P1 TO MAIN VALVE XAa1 ᥹Bs Atl
Bs
As
ARM OUT TO MAIN VALVE XAa2
P3 Btl
XAs
SWING
TO MAIN VALVE PaL XBs
LEFT
4ĳ2.0
Ma
XAtl
LCs
SWING TRAVEL XBtl
Py
Dr6
Dr2
P4 CP1
BTR
TO MAIN VALVE XBs Px CPG
R SWING ATR
STRAIGHT
XATR
TRAVEL (PTa)
XBTR
RIGHT
T P
P3 Pz CMR2 TRAVEL
TO MAIN VALVE R TRAVEL XATR
l
MR CMR1
ĳ0.7 ĳ0.7
ĳ0.7 d2 d1
d3
R TRAVEL PG P1 (P0) R1 P3 P2
L TRAVEL
P4
P1
TO MAIN VALVE R TRAVEL XBTR
TO MAIN VALVE L TRAVEL XATL
na
io
P2 TO MAIN VALVE L TRAVEL XBTL
TRAVEL PPC VALVE
A1 A2
PH1 a1 a2 PH2 Psv2
Psv1
at
D1 D2 D2 D1
a3 a4
P2 P3 P3 P2
rn
PT PT
BREAKER SET PRESS16.7±6.9kpa
te
BYPASS SET PRESS 0.3±0.02Mpa Pi1 Pi2
A
P1 P2
In
0.25Mpa Engine
FRONT REAR
P1 P4 P4 P1 0.45Mpa
As
A B B A
DR B1 B3 A3
ZX225-1108005
9.2 Air-Conditioning Electrical Circuit Diagram

CONTROL PANEL
ACM
10
6
7
11
17
18
19
21
22
23
26
27
28
29
30
31
32
35
36
1
2
3
4
5
8
9
12
13
14
15
16
20
24
25
33
34
CN-M30 CN-M29
11
10
10
12
13
14
15
16
6
7
1
2
3
4
5
6
7
11
17
18
19
1
2
3
4
5
8
9
8
9
12
13
14
15
16
.
0.5BrW
0.5BrY
0.5LgR
0.5WY
0.5GO
0.5WO
0.5OW
0.5GW
0.5RY
0.5VR
0.5RW
0.5WR
0.5LO
0.5BG
0.5BW
0.5VW
0.5BR
0.5BL
0.5BY
0.5PB
0.5YB
0.5PG
0.5Sb
0.5R
0.5B
pt
8
De
0.5LgR
0.5BrW
0.5BrY
0.5BW
0.5WO
0.5OW
0.5GW
0.5WR
0.5VW
0.5WY
0.5RY
0.5GO
0.5BY
0.5RW
0.5LO
0.5BG
0.5YB
0.5PG
0.5VR
0.5BR
0.5PB
0.5BL
0.5Sb
0.5R
0.5B
SWP SWP SWP
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
6
7
1
2
3
4
5
8
CN-M28 CN-M27 CN-M33
g
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
6
7
1
2
3
4
5
8
1
2
3
4
5
6
7
8
9
10
11
12
7
0.5LgR
0.5BrW
0.5RW
0.5BW
0.5WO
0.5OW
0.5GW
0.5WR
0.5BrY
0.5WY
0.5BG
0.5VW
0.5GO
0.5RY
0.5BY
0.5LO
0.5YB
0.5PG
0.5BR
0.5VR
0.5PB
0.5BL
0.5Sb
0.5R
0.5B
n
ti
SERVO MOTOR -
DIFFUSER CONVERSION
MV 2
SENSOR - INTERNAL TEMP.
FACE(DEF)
THI
FOOT
GND
Vz
e
Pt
6
7
6
5
4
3
2
1
CN-M34
1
2
7
6
5
4
3
2
1
rk 1
2
0.5GW
0.5OW
0.5BW
0.5GO
0.5BR
0.5BR
0.5Sb
050
CN-P15
2 2
1 1
Ma
S S 0.5WY FACE
7 7
0.5WR FOOT
6 6 SERVO MOTOR -
0.5BrW Pt
5 5 5
DIFFUSER CONVERSION
4 4
0.5BW Vz
3 3
2 2
0.5BR GND
1 1 MV I
l
CN-A30
2 2 0.5YB FRE
7 7
1 1 0.5VW REC
6 6
ECC
EC
T HA M
na 0.5WO
0.5BW
0.5BR
5
4
3
2
1
5
4
3
2
1
Pt
Vz
GND
SERVO MOTOR -
AIR RECIRCU/FRESH AIR
io
CN-E06 S 0.5PB Mcool
1
7 7
CN-M26 0.5VR Mhot
6 6
1
12 12 0.5BG Pt
5 5 SERVO MOTOR - A/M
11 11 4 4
TO CN-M26-A TO CN-E06-1 0.85W 0.5BW Vz
10 10 3 3
at
3 9 9 2B 2 2
0.5BR GND
8 8 1 1 MA M
TO CN-M26-7 TO CN-P15-1 0.5BW
7 7
TO CN-M26-7 TO CN-A30-2 0.5RW
6 6
2Br
5 5 1.25R
20A 4 4
TO CN-M26-2 TO CN-P15-2 3 3 0.5RY 5A
2 2
TO CN-M26-1 TO CN-A30-1 0.5BR
1 1
rn
24V 0.5BR
1 1 SENSOR - LOW TEMP
0.5PG
2 2
THF
1.25G
1.25RL 72C 40C 1.25G

2
1.25RL
1.25RL
2G
2RL
te
0.5BL
2G
2B
0.5BrY
0.85W
0.5LO
0.5R
0.5R
2RL
0.5lgR
2RL
2Br
2Br
0.5BR
0.5BY
2G
0.5B
4
3
4
3
3
4
2
1
3
4
2
1
2
1
2
1
2
1
3
4
2
1
2
1
3
4
2
1
PROTECTION
FOR TEMP.
2
1
2
1
In
DRIVING TRANSACTION OF
CIRCUIT INPUT SIGNEL
RL RL VOLTAGE
CORRECTION
R LC C R LB M MB BLC SPH L THW

1 RELAY - RELAY - BLOWER MOTOR - BLOWER SWITCH - HIGH/LOW PRESSURE SENSOR - WATER TEMP
COMPRESSOR CLUTCH
A B C D E F G H I J K L M N

9.3 Fuse Box Relay
.
HORN RELAY HEADLIGHT RELAY PILOT VALVE RELAY START RELAY PARKING RELAY TOP LIGHT RELAY
pt
De
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
8 1 2 3 4 5
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
1 2 3 4 5 1 2 3 4 5
31 23 32 33 24 34 105 27 606 105 11 12 13 64 63 65 72 71 70
g
7
n
e ti
6
rk
606 34 32 65 12 0 63 64
70 27 24 23 71 72 33 31 105 13 11
0
13
Ma
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
5 2 1 2 1 2 1
CN-661F
CN-661M
TO CHASSIS HARNESS CN-461M
TO CAB HARNESS N-161F
l
CONNECTOR 282080-1˄3˅
Fuse
F1
Fuse Box Harness
Rated Value
20A
System
Start Circuit
na 20
21
22
10
1
io
2
29 3
F2 10A Charging Indication
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F14 F15 F16 F17 42 4
F3 5A Horn Circuit 49 5
F4 15A Work Lamp 6
at
3 22 10 23 24 25 20 b 26 38 28 29 42 43 49 27 70
7
F5 5A Wiper & Washer 43 8
F6 10A Speaker 9
20 10
F7 10A Cab Light
rn
11
F8 20A Air Conditioner 12
21
F9 5A Access Lamp
20 b CN-241F
2
F10 5A Monitor
te
TO CHASSIS HARNESS CN-441M

F11 20A Controller 23 24 25 26
F14 10A Aux. Controller 27 28 38 70 10
F15 15A Cigar Lighter 1 2 3 4 5 6 7 8 9 10 11 12
In
F16 10A Solenoid Valve GP

F17 10A Top Light
1 CN-221M
㟇偒偊ᅸ㒓ᴳCN-121F

9.4 Control Switches and Monitor Electrical Diagram
.
START SWITCH WORK LAMP SWITCH WIPER SWITCH WASHER SWITCH
pt
TERMINAL B BR ACC R1 R2 C CN-303M CN-304M CN-305M
HEAT 50
1
506
OFF 1 3 5 7 1 3 5 7 1 3 5 7 2
De
00
33 24 3
8
ON 35 H 25 35 L 36 37 25
35 L
4
START 72 5
70
6
22 13 16 11
18
7
17 8
g
9
10
7
11
n
12
ti
CN-331F
TO CAB HARNESS CN-131M
e
6
rk
25
1
33
2
35 H 3
36
50 506 00 18 16 4
72 70 37
Ma
5
0 6
10 14 17 0 10
5 1 2 3 1 3 5 7 1 3 5 7 7
11
8
13
9
CN-302F CN-306M CN-307M 14
10
F-310 F-311 F-312 F-313 22
TO CONTROL DIAL SWITCH PREHEAT SWITCH TOP LIGHT SWITCH 11
l
24 12
na CN-7-707M CN-7-706M
CN-332M
TO CAB HARNESS CN-132F
io
CN-7-111F
CN-7-705M
CIGAR LIGHTER SUNLIGHT SENSOR TO CHASSIS HARNESS CN-1-111M
1 2
1 1 2 0
1
22
2
at
3 CAN+ 0 100 29
2
CAN+ 61 60
3
CAN- 3
CAN- 4
4 0
5
100
5 6
rn
60 7
6
61 8
24V 7
2 29
24V 8
te
22
GND 9
CAN+
0 A
10 CAN-
GND B
11
In
0 C
12 A B
1 CN-7-709 CN-7-112F
A B
120

9.5 Operator Cab Electrical Circuit Diagram
TO FUSE BOX RELAY HARNESS CN-221M TO CHASSIS HARNESS CN-442F TO FUSE BOX RELAY HARNESS CN-661M
9
CN-121F CN-142M CN-161F
.
TO WIPER MOTOR
CN-112M
pt
TO ACCESS LAMP
1 2 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
0 37 0 28 27 28 38 70 22 70 27 24 23 71 72 33 31 0 105
1020 b23 24 25 26 50 506 0060 a 57 18 17 61a 14 13 0 10 18 13 11
CN-131M CN-113M
De
TO CONTROL SW
8
MONITOR HARNESS CN-331F 23
2 1
2 CN-104M
50 31
1 1 TO HORN S/W
2 506
00
3
35 L
g
4 105
72 1 CN-106F
7
5
n
TO PILOT S/W
70 27 2
6
18
ti
7
8 17
e
10 1
6
11 25 2
rk
36
12 3 CN-110M
TO WIPER HARNESS
35 H 4
CN-132F
35 L 5
Ma
TO CONTROL SW MONITOR HARNESS CN-332M
25 6
5 1
2 33
3 35 H
57
4 36
1
l
5 37 61a
4
00 60 a
4
6
7
8
10
11
na 0
38
5
6
7
CN-207F
TO A/C PANEL
13
io
9
38 8
10 14
22
11
24
at
3
12
26 8
CN-107M 0 7
rn
TO RADIO PANEL
20 b 71 6
1
R+ 0 5 CN-150M
2 L- TO SPEAKER,
2
L+ 4
3 CAB LAMP HARNESS
te
L+
4 0 3
R-
5 20 b 2
R- R+
6 1
In
L-
7
1
TO CONSOLE GND

9.6 Chassis Electrical Circuit Diagram
CN-616F CN-441M CN-501M CN-1-111M CN-442F

CN-152M CN-153M
GROUND 1 1 2 1 2 TO FUSE BOX RELAY HARNESS CN-241F TO CONTROL SW MONITOR HARNESS CN-7-111F TO CAB HARNESS CN-142M
2 0 TO GPS
9
3 CN-204F CN-412F CN-7-112F F-106 CN-101M F-108 CN-113M
.
24V POWER 4
2 1 CN-152M
5
6
42
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 2 1
43 0 CAN+ B
1 2 3 A B C
CAN- CAN+ CAN- 508 509 510 42 511 2 1
7
22 29 42 49 43 20 20 21 21 0 22 29 0 49 60a 61a 50 506 00 60 a 57 18 17 61a 14 13 0 10
pt
8
9
240/0.25W
FUEL LEVEL INPUT 10
11
509
AIN16 12 T-119
13 B TO PWR GND
14
T-110
15
507 0
T-102
13
De
16
8 17 T-101TO BAT RELAY

RPM SENSOR INPUT 18
20
19
108 B T-104
20
21
22 B06 21
23 B05 T-103
B07 1 2
24 CN-702F
25
57
26 T-107TO COMPRESSOR CLUTCH
27 0
28 0 57 T-111
1
g
2
WATER TEMP INPUT 29
30 510
HYD OIL TEMP INPUT
31 511 CN-109M
7 32
21 T-108
n
FUEL CTRL DIAL VOLT 33
34
506 16 TO PREHEAT FUSE
35
36
T-109
37
108 A
ti
RMP SENSOR INPUT
38
39
108 A
40
B04 CN-448M
41
42 B07 108 B
43
B08 50 1
44
507 2
45
MT- 3 CN-445M
e
46
M OIL PRESS INPUT 47 4 TO THROTTLE MOTOR
6 PRESS INPUT - TRAVEL(L) 48
508 00 5
200 MT+
BUCKET DUMP PRESS INPUT 49
204 6
BOOM LOWER PRESS INPUT
rk
50 17
207
ARM OUT PRESS INPUT 51 TO PREHEAT FUSE
202 16
REAR PUMP PRESS INPUT 52
53
502 17
s GND
00
s GND 54
00 18 TO PREHEAT RELAY
s PWR 55
50 0 12
56
CAN- 57
CAN- 21
58 ALTERNATOR TERM B
10
Ma
CAN+ 59
60
CAN+ 14 ALTERNATOR TERM L/R
61 B01 47
62
ALTERNATOR TERM P
5 63
64 12a 1
65 14 2
PRESS INPUT - TRAVEL (R) 66 10 CN-613F
67
201 3
SWING PRESS INPUT
BUCKET CURL PRESS INPUT 68
208 47 4 TO SAFETY RELAY
BOOM RAISE PERSS INPUT 69
205 5
206 0 6
ARM IN PRESS INPUT 70
FRONT PUMP PRESS INPUT 71
203
l
501 22 1
s GND 72
00 B01 1
s PWR 73
50 B02 2 64 2
74
s PWR 50 B03 3 63 3 CN-801F
75 CN-158M 0 4
4
CAN+
CAN-
CN-615F
76
77
78
79
80
81
CAN+
CAN-
B02
B03
B01
607
B04 4
B05 5
B06 6
B07 7
B08 8
CALIBRATOR CONNECTOR
na 65 5
702
6
1
TO PARK MOTOR
CN-113F
io
SPEED CONTROL OUTPUT 82
83
F PUMP PRESS SENSOR R PUMP PRESS SENSOR F PUMP SOL
84
42 0 2 PROP VALVE
85 1 CN-115M CN-116M
86
F. PUMP PRPTL VALVE OUTPUT 87 0 2
88
702 703
R. PUMP PRPTL VALVE OUTPUT
1
A B C
703
89
90
CN-159M A B C CN-114F
R PUMP SOL
at
3 CONNECTOR 282080-1
91
50 00 501 50 00 502 0
92 2 PROP VALVE
93 0 606 0 607
1 2 1 2
94
95 606
96
1
SWING PRTY PRPTL VALVE OUTPUT 97
CN-136F
608
BUCKET CONFL PRPTL VALVE OUTPUT 98
604 0 PILOT SOL VALVE
2
rn
99
100
101
102 604 1
103
CN-134F
FUEL CTRL MOTOR SIGNAL OUTPUT 104
MT+ BKT CONFLUENCE
105 0 SOL VALVE
2 106
2
107
te
108
608
109 1
110
CN-133F
111 SWING PRIORITY
FUEL CTRL MOTOR SIGNAL OUTPUT 112 0 2 SOL VALVE
GROUND 113
GROUND 114
0 606 34 32 65 12 0 63 64 50 00 50 00 201 50 00 202 50 00 208 50 00 205 50 00 207 50 00 206 50 00 204 50 00 203
115
0
607
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 A B C A B C A B C A B C A B C A B C A B C A B C A B C 1
In
116
117 CN-131F
24V POWER 118
42
HI/LO TRAVEL
24V POWER 119
42 0 2 SPD SOL VALVE
120
CN-120M CN-121M CN-122M CN-123M CN-124M CN-125M CN-126M CN-127M CN-128M
1 121
CN-461M CN-112M 12 12 a 0 21
122
0 0 34
1 2 2 1
L TRAVEL R TRAVEL ARM-OUT SWING BKT DIG BOOM DOWN BOOM UP BKT DUMP ARM IN
1 2 1 2 TO FUSE BOX RELAY HARNESS CN-661F 282104-1
CN-111F PRESS SENSOR PRESS SENSOR PRESS SENSOR PRESS SENSOR PRESS SENSOR PRESS SENSOR PRESS SENSOR PRESS SENSOR PRESS SENSOR
TO WORK LAMP F-104 F-103 TO START MOTOR
CN-102M CN-106M TO HORN

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www.sanygroup.

com Quality Changes the World

Shop Manual SY195/205/215/225C9

Crawler Hydraulic Excavator

SANY HEAVY MACHINERY LIMITED

Tel: (86) 21 5700 8518

Documentation No.: B06T03ENAN1-SY195/205/215/225C9

Shop Manual - November 2014 I

2.2.16 Fire Extinguisher and Emergency Exits ..................................................... 2-14

4 Structure and Function

II Shop Manual - November 2014

4.3.2 Idler .............................................................................................................. 4-16

Shop Manual - November 2014 III

4.6.6.1 Operation of components.................................................................... 4-95

IV Shop Manual - November 2014

4.9.4.1 Electrical positive flow control ........................................................... 4-175

6 Testing and Adjusting

Shop Manual - November 2014 V

6.5.1 Testing.......................................................................................................... 6-13

VI Shop Manual - November 2014

7.6 Troubleshooting of Electrical System (E - Mode)................................................... 7-63

8 Disassembly and Assembly

Shop Manual - November 2014 VII

8.12.1 Removal ..................................................................................................... 8-46

VIII Shop Manual - November 2014

Shop Manual - November 2014 IX

8.37.2 Removal ................................................................................................... 8-152

X Shop Manual - November 2014

1.3.2 Points to remember when handling hydraulic equipment ............................ 1-16

1.4.2 Hose connector tightening torque table ....................................................... 1-19

1.4.3 Connection of O-rings .................................................................................. 1-20

1.5 Table of Standard Tightening Torques .................................................................. 1-21

1.8 Maintenance of Half Flanges ................................................................................. 1-23

Shop Manual - November 2014 1-1

1-2 Shop Manual - November 2014

1.1 How to Read the Shop Manual

Structure and function

Testing and adjusting

Disassembly and assembly

Shop Manual - November 2014 1-3

2. Revision and distribution

Symbol Item Remarks

Special safety precautions are necessary when performing

Special technical precautions or other precautions for pre-

Weight of parts of component or parts. Caution necessary

torque during assembly.

Coat Places to be coated with adhesives, etc. during assembly.

Places where oil, etc. must be drained, and quantity to be

1-4 Shop Manual - November 2014

1.2 Terms for Maintenance Standard

The maintenance standard values necessary

1. Standard size and tolerance

● To be accurate, the finishing size of parts

● To specify a finishing size of a part, a tem-

indicated on the right side of the standard

Standard size Tolerance

NOTE: The tolerance may be indicated in

the text and a table as [standard size (upper Std.size F 60

● Indication of size of rotating shaft and